Anti-reflective formed article and method for preparation thereof, and mold for anti-reflective formed article

ABSTRACT

An anti-reflection molding has a transparent substrate and an anti-reflection layer provided at least on a surface of the transparent substrate, an interface of a transparent window on which the anti-reflection layer is formed has an average surface roughness Ra of between 2.0 and 150 nm, and the molding has a curved surface having a radius of curvature of not less than 40 mm and protruding on a surface side, or a flat surface, in the transparent window.

This application is a National Stage of PCT/JP01/09095, filed Oct. 17,2001.

TECHNICAL FIELD

The present invention relates to an anti-reflection molding that is usedso that a display (a member having a function as a display screen) orthe like located therebehind, such as various displays of portabletelephone, video camera, digital camera, equipment for automobile, PDA(Personal Digital Assistant), monitor for personal computer, electronicpaper that is an electronic display device as light, thin, and flexibleas paper, television, and the like, various electronic equipment such aselectronic equipment for outdoor display, and such various displaymembers of equipment other than electronic equipment as an outdoorbulletin board, picture frame, photo stand, clock, and window glass, maybe seen through the molding, relates to a method of manufacturing thesame, and relates to a mold for the anti-reflection molding.

BACKGROUND ART

A display section of a portable telephone, a video camera, a digitalcamera, equipment for an automobile, and the like is configured incombination with a liquid crystal panel or an organic EL panel or in thelike manner. The display section is covered with a cover componentcomposed of a transparent substrate shaped like a convex lens or atransparent substrate formed with a pattern such as a border, forpurposes of prevention of breakage in the liquid crystal panel,magnification of displayed items on the liquid crystal panel, decorationof a neighborhood of the liquid crystal panel, or the like.

A transparent window of such a cover component as described above isrequired to have a glare-proof property in order that displayed picturesmay be seen comfortably. Besides, a hard-coat property is required thatis excellent in marring resistance, chemical resistance, weatherresistance, and the like. This is why formation of an anti-reflectionlayer, that makes use of Fresnel reflection and interference of light,is necessary.

In this method, it is extremely important to control a thickness of theanti-reflection layer, and a thickness equal to a quarter wavelengthmaximizes an anti-reflection effect because reflected light from a filmsurface and reflected light from a film-substrate interface then canceleach other out, and thus a reflectance decreases. For an anti-reflectionlayer having an index of refraction of 1.36, for example, an optimalthickness of the anti-reflection layer is on the order of 0.1 μm oncondition that a central wavelength of transmitted light is 550 nm.

It is, however, extremely difficult to form such an anti-reflection filmlayer with a uniform thickness on a transparent substrate, and thus anissue arises wherein it is difficult to achieve an expectedanti-reflection effect. Provided that a general shape of the transparentsubstrate is three-dimensional, particularly, it is extremely difficultto form a film with a uniform thickness thereon and it is difficult toachieve an expected anti-reflection effect.

Besides, there is another issue in that the anti-reflection layerdescribed above is inferior in terms of a hard-coat property.

An object of the present invention is therefore to provide ananti-reflection molding that cancels such defects as described above andthat has an excellent anti-reflection effect and an excellent hard-coatproperty, a method of manufacturing the same, and a mold and a transfermember for the anti-reflection molding.

SUMMARY OF THE INVENTION

For achievement of the above object, the present invention is configuredas follows.

According to a first aspect of the present invention, there is provideda method of manufacturing anti-reflection molding, comprising:

placing a decorating sheet having at least a hard-coat layer formed on asubstrate sheet to come, on a substrate sheet side thereof, into contactwith a cavity surface of a mold that is a curved surface having a radiusof curvature of not less than 40 mm, or a flat surface, in an areacorresponding to a transparent window;

injecting transparent molten resin into the mold to obtain an integratedbody of the decorating sheet and a transparent substrate composed of theresin;

subsequently peeling the substrate sheet from the integrated body toform a curved surface having a radius of curvature of not less than 40mm and protruding on a surface side thereof, or a flat surface, that hasan average surface roughness Ra of between 2.0 and 150 nm in thetransparent window; and

subsequently forming an anti-reflection layer on a surface side of thetransparent substrate.

According to a second aspect of the present invention, there is provideda method of manufacturing an anti-reflection molding, comprising:

placing a decorating sheet having at least a hard-coat layer formed on asubstrate sheet to come, on a side having the hard-coat layer, intocontact with a cavity surface of a mold that is a curved surface havinga radius of curvature of not less than 40 mm, or a flat surface, in anarea corresponding to a transparent window;

injecting transparent molten resin into the mold to obtain an integratedbody of the decorating sheet and of a transparent substrate composed ofthe resin and to form a curved surface having a radius of curvature ofnot less than 40 mm and protruding on a surface side thereof in a shapeof the transparent window, or a flat surface, that has an averagesurface roughness Ra of between 2.0 and 150 nm in the transparentwindow; and

subsequently forming an anti-reflection layer on a surface side of thetransparent substrate.

According to a third aspect of the present invention, there is provideda method of manufacturing an anti-reflection molding as defined in anyone of the first and second aspects, wherein the decorating sheet hasthe hard-coat layer, a partial pattern layer with a pattern excludingthe transparent window, and an adhesive layer that are formed at leaston the substrate sheet.

According to a fourth aspect of the present invention, there is provideda method of manufacturing an anti-reflection molding as defined in thethird aspect, wherein an anti-fouling layer is formed on theanti-reflection layer.

According to a fifth aspect of the present invention, there is provideda mold for anti-reflection molding by which an anti-reflection moldingis molded that has at least a hard-coat layer formed on a surface of atransparent substrate, and that has a curved surface having a radius ofcurvature of not less than 40 mm and protruding on a surface sidethereof in a transparent window, or a flat surface, with an averagesurface roughness Ra of between 2.0 and 150 nm in the transparentwindow,

with the mold for anti-reflection molding having a cavity surface thatis a curved surface having a radius of curvature of not less than 40 mm,or a flat surface, in an area corresponding to the transparent window.

According to a sixth aspect of the present invention, there is provideda mold for anti-reflection molding as defined in the fifth aspect,wherein the cavity surface has an average surface roughness Ra ofbetween 2.0 and 170 nm in the area corresponding to the transparentwindow.

According to a seventh aspect of the present invention, there isprovided an anti-reflection molding comprising:

a transparent substrate; and an anti-reflection layer provided at leaston a surface of the transparent substrate,

in which an interface of a transparent window having the anti-reflectionlayer formed thereon has an average surface roughness Ra of between 2.0and 150 nm, and in which the transparent window has a curved surfacehaving a radius of curvature of not less than 40 mm and protruding on asurface side, or a flat surface.

According to an eighth aspect of the present invention, there isprovided an anti-reflection molding as defined in the seventh aspect,wherein a partial pattern layer with a pattern excluding the transparentwindow is provided between the transparent substrate and theanti-reflection layer.

According to a ninth aspect of the present invention, there is providedan anti-reflection molding as defined in any one of the seventh andeighth aspects, wherein a hard-coat layer is formed between thetransparent substrate and the anti-reflection layer.

According to a 10th aspect of the present invention, there is providedan anti-reflection molding as defined in the ninth aspect, wherein ananti-fouling layer is provided on the anti-reflection layer.

According to an 11th aspect of the present invention, there is providedan anti-reflection molding as defined in any one of the seventh andeighth aspects, wherein a central visual recognition area in thetransparent window has an average surface roughness Ra of between 2 and35 nm, and wherein a peripheral visual recognition area, along aperiphery of the central visual recognition area in the transparentwindow, has an average surface roughness Ra of between 35 and 85 nm.

According to a 12th aspect of the present invention, there is providedan anti-reflection transfer member in which, on a substrate sheet, atleast an anti-reflection layer is provided, directly or with a moldrelease layer therebetween, and in which a surface of the substratesheet or a surface of the mold release layer has an average surfaceroughness Ra of between 2.0 and 150 nm.

According to a 13th aspect of the present invention, there is providedan anti reflection transfer member as defined in the 12th aspect,wherein the surface of the substrate sheet or the surface of the moldrelease layer has an average surface roughness Ra of between 5.0 and 140nm.

According to a 14th aspect of the present invention, there is providedan anti-reflection transfer member as defined in the 13th aspect,wherein the surface of the substrate sheet or the surface of the moldrelease layer has an average surface roughness Ra of between 5.0 and 80nm.

According to a 15th aspect of the present invention, there is providedan anti-reflection transfer member as defined in any one of the 12ththrough 14th aspects, wherein a hard-coat layer composed of ultravioletcurable resin, electron beam curable resin, or thermosetting resin isprovided on the anti-reflection layer.

According to a 16th aspect of the present invention, there is providedan anti-reflection transfer member as defined in any one of the 12th and13th aspects, wherein a pattern layer is formed in an area excluding atransparent window.

According to a 17th aspect of the present invention, there is providedan anti-reflection member in which two anti-reflection component layershaving interfaces with uneven shapes between both the layers are stackedon a transparent window of a transparent substrate.

According to an 18th aspect of the present invention, there is providedan anti-reflection member as defined in the 17th aspect, wherein theuneven shapes exhibit an average surface roughness Ra of between 0.2 and1.0 μm.

According to a 19th aspect of the present invention, there is providedan anti-reflection member as defined in any one of the 17th and 18thaspects, wherein an upper layer of the anti-reflection component layersis composed of thermosetting resin, ultraviolet curable resin, orelectron beam curable resin.

According to a 20th aspect of the present invention, there is providedan anti-reflection member as defined in the 19th aspect, wherein alow-reflectance layer having a reflectance lower than that of the upperlayer is layered on the upper layer of the anti-reflection componentlayers.

According to a 21st aspect of the present invention, there is providedan anti-reflection member as defined in the 20th aspect, wherein ananti-fouling layer is layered on the low-reflectance layer.

According to a 22nd aspect of the present invention, there is providedan anti-reflection member as defined in any one of the 17th and 18thaspects, wherein a pattern layer is formed outside the transparentwindow.

According to a 23rd aspect of the present invention, there is provided amethod of manufacturing an anti-reflection member, comprising:

setting a transfer member wherein at least two anti-reflection componentlayers having interfaces with uneven shapes between both the layers areformed on a substrate sheet, in a mold to bring the substrate sheet intocontact with a cavity surface;

injecting transparent molten resin into the mold to obtain an integratedbody of the transfer member and a transparent substrate composed of theresin; and

subsequently peeling the substrate sheet from the integrated body.

According to a 24th aspect of the present invention, there is provided amethod of manufacturing an anti-reflection member as defined in the 23rdaspect, wherein the uneven shapes exhibit an average surface roughnessRa of between 0.2 and 1.0 μm.

According to a 25th aspect of the present invention, there is provided amethod of manufacturing an anti-reflection member as defined in any oneof the 23rd and 24th aspects, wherein an upper layer of theanti-reflection component layers is composed of thermosetting resin,ultraviolet curable resin, or electron beam curable resin.

According to a 26th aspect of the present invention, there is provided amethod of manufacturing an anti-reflection member as defined in any oneof the 23rd and 24th aspects, wherein a low-reflectance layer having areflectance lower than that of the upper layer is formed on the upperlayer of the anti-reflection component layers.

According to a 27th aspect of the present invention, there is provided amethod of manufacturing an anti-reflection member as defined in the 26thaspect, wherein an anti-fouling layer is formed on the low-reflectancelayer.

According to a 28th aspect of the present invention, there is provided amethod of manufacturing an anti-reflection member as defined in any oneof the 23rd and 24th aspects, wherein a pattern layer is formed outsidethe transparent window.

According to a 29th aspect of the present invention, there is providedan anti-reflection molding comprising:

a transparent substrate;

two anti-reflection component layers stacked on a transparent window ofthe transparent substrate and having interfaces with uneven shapesbetween both the layers;

a hard-coat layer provided on the two anti-reflection component layers;and

an anti-reflection layer provided on the hard-coat layer,

in which an interface of the transparent window having theanti-reflection layer formed thereon has an average surface roughness Raof between 2.0 and 150 nm, and in which the transparent window has acurved surface having a radius of curvature of not less than 40 mm andprotruding on a surface side thereof, or a flat surface.

According to a 30th aspect of the present invention, there is providedan anti-reflection transfer member in which, on a substrate sheet, atleast an anti-reflection layer is provided, directly or with a moldrelease layer therebetween, in which a surface of the substrate sheet ora surface of the mold release layer has an average surface roughness ofRa between 2.0 and 150 nm, and in which two anti-reflection componentlayers having interfaces with uneven shapes between both the layers arestacked on a part of a surface of the anti-reflection layer or the moldrelease layer opposite to the substrate sheet and facing a transparentwindow.

BRIEF DESCRIPTION OF DRAWINGS

These and other aspects and features of the present invention willbecome clear from the following description taken in conjunction withthe preferred embodiments thereof with reference to the accompanyingdrawings, in which:

FIG. 1A is a sectional view illustrating an anti-reflection molding of afirst embodiment of the present invention;

FIG. 1B is a sectional view illustrating an anti-reflection molding ofthe first embodiment of the present invention;

FIG. 1C is a sectional view illustrating an anti-reflection molding ofthe first embodiment of the present invention;

FIG. 2 is a sectional view illustrating a decorating sheet that is usedin a method of manufacturing the anti-reflection molding of the firstembodiment of the present invention;

FIGS. 3A and 3B are sectional views illustrating a step in the method ofmanufacturing the anti-reflection molding of the first embodiment of thepresent invention;

FIG. 4 is a sectional view illustrating a step in the method ofmanufacturing anti-reflection moldings of the first embodiment of thepresent invention;

FIG. 5 is a sectional view illustrating a step in the method ofmanufacturing anti-reflection moldings of the first embodiment of thepresent invention;

FIG. 6 is a sectional view illustrating a decorating sheet that is usedin the method of manufacturing anti-reflection moldings of the firstembodiment of the present invention;

FIG. 7 is a sectional view illustrating a step in the method ofmanufacturing anti-reflection moldings of the first embodiment of thepresent invention;

FIG. 8 is a sectional view illustrating a step in the method ofmanufacturing anti-reflection moldings of the first embodiment of thepresent invention;

FIG. 9 is a graph for obtainment of an average surface roughness Ra inthe first embodiment of the present invention;

FIG. 10 is a sectional view illustrating a mold for the anti-reflectionmoldings of the first embodiment of the present invention;

FIG. 11 is a sectional view illustrating an anti-reflection molding ofthe first embodiment of the present invention;

FIG. 12 is a sectional view illustrating an anti-reflection molding ofthe first embodiment of the present invention;

FIGS. 13A, 13B, and 13C are schematic sectional views illustrating howan anti-reflection effect varies with respect to different averagesurface roughnesses Ra;

FIG. 14 is an explanatory diagram illustrating a relationship betweenrequired reflectances and surface roughnesses Ra in various examples ofanti-reflection molding of the first embodiment of the presentinvention;

FIG. 15 is a perspective view of an anti-reflection molding,illustrating various areas in anti-reflection moldings of theembodiments of the present invention;

FIG. 16 is a sectional view of the anti-reflection molding, illustratingvarious areas in the anti-reflection moldings of the embodiments of thepresent invention;

FIG. 17 is a sectional view illustrating a mold for molding that is usedin the method of manufacturing anti-reflection moldings of the firstembodiment of the present invention;

FIG. 18 is a sectional view illustrating an anti-reflection transfermember of a second embodiment of the present invention;

FIG. 19 is a sectional view illustrating an anti-reflection moldingmanufactured with use of the anti-reflection transfer member of thesecond embodiment of the present invention;

FIG. 20 is a perspective view illustrating an anti-reflection moldingmanufactured with use of the anti-reflection transfer member of thesecond embodiment of the present invention;

FIG. 21 is a sectional view illustrating a step of manufacturing ananti-reflection molding with use of the anti-reflection transfer memberof the second embodiment of the present invention;

FIG. 22 is a sectional view illustrating a step of manufacturing theanti-reflection molding with use of the anti-reflection transfer memberof the second embodiment of the present invention;

FIG. 23 is a sectional view illustrating the anti-reflection molding ofthe first embodiment of the present invention, for comparison with theanti-reflection molding of the second embodiment of the presentinvention;

FIG. 24 is a sectional view illustrating the anti-reflection molding ofthe second embodiment of the present invention;

FIG. 25 is a sectional view illustrating an anti-reflection transfermember of the second embodiment of the present invention;

FIG. 26 is a sectional view illustrating an anti-reflection member of athird embodiment of the present invention;

FIG. 27 is a sectional view illustrating a transfer member for use in amethod of manufacturing the anti-reflection member of the thirdembodiment of the present invention;

FIG. 28 is a perspective view illustrating an anti-reflection member ofthe third embodiment of the present invention;

FIG. 29 is a sectional view illustrating a step of the method ofmanufacturing an anti-reflection member of the third embodiment of thepresent invention;

FIG. 30 is a sectional view illustrating a step of the method ofmanufacturing the anti-reflection member of the third embodiment of thepresent invention;

FIG. 31 is a sectional view illustrating a conventional anti-reflectionmember;

FIG. 32 is a sectional view illustrating an anti-reflection member ofthe third embodiment of the present invention;

FIG. 33 is a sectional view illustrating an anti-reflection member ofthe third embodiment of the present invention;

FIG. 34 is a sectional view illustrating an anti-reflection member ofthe third embodiment of the present invention;

FIG. 35 is a sectional view illustrating an anti-reflection member inaccordance with a combination of the first embodiment and the thirdembodiment of the present invention; and

FIG. 36 is a sectional view illustrating an anti-reflection member inaccordance with a combination of the second embodiment and the thirdembodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before description of the present invention proceeds, it is to be notedthat like parts are designated by like reference numerals throughout theaccompanying drawings.

First Embodiment

A first embodiment of the present invention will be described in detailwith reference to the drawings.

FIG. 1A is a sectional view illustrating an anti-reflection molding ofthe first embodiment of the present invention. FIG. 1B is a sectionalview illustrating an anti-reflection molding of the first embodiment ofthe present invention. FIG. 1C is a sectional view illustrating ananti-reflection molding of the first embodiment of the presentinvention. FIG. 2 is a sectional view illustrating a decorating sheetthat is used in a method of manufacturing anti-reflection moldings ofthe first embodiment of the present invention. FIGS. 3A through FIG. 5are sectional views illustrating steps in a method of manufacturinganti-reflection moldings of the first embodiment of the presentinvention. FIG. 6 is a sectional view illustrating a decorating sheetthat is used in the method of manufacturing anti-reflection moldings ofthe first embodiment of the present invention. FIGS. 7 and 8 aresectional views illustrating steps in the method of manufacturinganti-reflection moldings of the first embodiment of the presentinvention. FIG. 9 is a graph for obtainment of an average surfaceroughness Ra in the first embodiment of the present invention. FIG. 10is a sectional view illustrating a mold for the anti-reflection moldingsof the first embodiment of the present invention. FIGS. 11 and 12 aresectional views illustrating anti-reflection moldings of the firstembodiment of the present invention. FIGS. 13A through 13C are schematicsectional views illustrating how an anti-reflection effect varies withrespect to different average surface roughnesses Ra. FIG. 14 is anexplanatory diagram illustrating a relationship between requiredreflectances and surface roughnesses Ra in various examples ofanti-reflection molding of the first embodiment of the presentinvention. FIG. 15 is a perspective view illustrating an anti-reflectionmolding of the first embodiment of the present invention. FIG. 16 is asectional view illustrating the anti-reflection molding of the firstembodiment of the present invention. FIG. 17 is a sectional viewillustrating a mold for molding that is used in the method ofmanufacturing anti-reflection moldings of the first embodiment of thepresent invention.

In the drawings, reference numeral 1 denotes a transparent substrate,numeral 2 denotes an adhesive layer, numeral 3 denotes a mold releaselayer, numeral 4 denotes a hard-coat layer, numeral 5 denotes ananti-reflection layer, numeral 7 denotes a substrate sheet, numeral 8denotes an anti-reflection molding, numeral 9 denotes a decoratingsheet, and numeral 10 denotes a metal mold for manufacturing theanti-reflection molding 8.

The anti-reflection molding 8 of the first embodiment of the presentinvention is composed of the substrate sheet 7, the decorating sheet 9having at least the hard-coat layer 4 formed on the substrate sheet 7,the transparent substrate 1 made of resin that is integrated with thedecorating sheet 9, and the anti-reflection layer 5 provided on asurface side of the transparent substrate 1. In a transparent window isformed a curved surface having a radius of curvature of not less than 40mm and protruding on a surface side in the transparent window, or a flatsurface that has an average surface roughness Ra of between 2.0 and 150nm.

In the method of manufacturing the anti-reflection molding 8 inaccordance with the first embodiment of the present invention, thedecorating sheet 9 (see FIG. 2) having at least the hard-coat layer 4formed on the substrate sheet 7 is placed so that the hard-coat layer 4is received within a cavity 10B having a cavity surface 10A (see FIG. 10and FIG. 3A) of the metal mold 10 that is a curved surface having aradius of curvature of not less than 40 mm, or is a flat surface in anarea corresponding to the transparent window (see FIG. 3A), transparentmolten resin 1A is injected into the cavity 10B of the metal mold 10 sothat an integrated body of the decorating sheet 9 and the transparentsubstrate 1 formed of the resin 1A is obtained (see FIG. 4), thesubstrate sheet 7 is subsequently peeled from integrated body 100 sothat a curved surface having a radius of curvature of not less than 40mm and protruding on the surface side in the transparent window 110A, ora flat surface that has an average surface roughness Ra of between 2.0and 150 nm is formed in the transparent window (see FIG. 4), and theanti-reflection layer 5 is subsequently formed on the surface side ofthe transparent substrate 1 (see FIG. 1A).

Alternatively, a position of the decorating sheet 9 in the metal mold 10may be reversed. That is, a configuration is made as follows. Thedecorating sheet 9 is placed so that the substrate sheet 7 (see FIG. 3B)comes into contact with the cavity surface 10A (see FIG. 10 and FIG. 3B)of the metal mold 10 that is a curved surface having a radius ofcurvature of not less than 40 mm, or is a flat surface in an areacorresponding to the transparent window, transparent molten resin 1A isinjected into the cavity 10B of the metal mold 10 so that an integratedbody of the decorating sheet 9 and the transparent substrate 1 formed ofthe resin 1A is obtained, the substrate sheet 7 is subsequently peeledfrom the integrated body so that a curved surface having a radius ofcurvature of not less than 40 mm and protruding on the surface side inthe transparent window 110A, or is a flat surface, that has an averagesurface roughness Ra of between 2.0 and 150 nm, is formed in thetransparent window 110A (see FIG. 8), and the anti-reflection layer 5 issubsequently formed on the hard-coat layer 4 on the surface side of thetransparent substrate 1 (see FIG. 1B).

In the anti-reflection molding of the first embodiment of the presentinvention, it is important that an average surface roughness Ra of aninterface of the transparent window on which the anti-reflection layer 5is formed is between 2.0 and 150 nm, and that the molding has a curvedsurface having a radius of curvature of not less than 40 mm or a flatsurface in the transparent window.

A test was conducted concerning an order on or below which the averagesurface roughness Ra of the surface of the molding has to be forformation of the anti-reflection layer 5 with a uniform thickness. Metalmolds 10 having surfaces grained to various degrees were produced,moldings having various average surface roughnesses Ra were produced,and the average surface roughnesses Ra were measured with a measuringapparatus (F3500D produced by Kosaka Laboratory Ltd.) in conformancewith Japanese Industrial Standard (JIS) B0601-1994. To JIS B 0601correspond ISO468:82, ISO3274:75, ISO4287-1:84, ISO4287-2:84, andISO4288:85. Subsequently, anti-reflection layers 5 were formed on thesame condition, and reflectances at 550 nm were measured with aspectrophotometer. As a result of measurement of anti-reflection effectsof the moldings in this manner, as shown in Table 1, it was found thatan anti-reflection effect can be obtained with average surfaceroughnesses Ra of a surface of a molding being not more than 150 nm.More preferably, the average surface roughness Ra of the surface of themolding is not more than 80 nm.

It was also found that production with an average surface roughness Raof less than 2.0 nm is extremely difficult to achieve, and that atolerance of thickness of the anti-reflection layer 5 and a reflectanceof the anti-reflection molding 8 manufactured with the layer hardlychange with the average surface roughnesses Ra being not more than 35nm. Herein, the reflectance is a numerical value obtained with ameasuring method of ISO/DIS13406-2.

FIGS. 13A through 13C are schematic sectional views illustrating how theanti-reflection effect varies with respect to different average surfaceroughnesses Ra. The anti-reflection layer 5 was formed so as to have athickness of 100 nm. On condition that the average surface roughness Rais 5 nm (see FIG. 13A), for example, thicknesses of the anti-reflectionlayer 5 are generally uniform, there occurs moderate interferencebetween reflected rays of light α and α′, β and β′, and a uniform andexcellent anti-reflection effect can be achieved throughout theanti-reflection layer 5. On condition that the average surface roughnessRa is 150 nm (see FIG. 13B), thicknesses of the anti-reflection layer 5partially exhibit a variation, degrees of interference between reflectedrays of light α and α′, β and β′ may be different, and ananti-reflection effect may decrease slightly and locally on theanti-reflection layer 5. On condition that the average surface roughnessRa is 400 nm (see FIG. 13C), thicknesses of the anti-reflection layer 5are not uniform, there occurs no interference between reflected rays oflight α and α′, β and β′, and no anti-reflection effect is achievedthroughout the anti-reflection layer 5.

As shown in FIG. 14, required reflectances differ according to uses ofthe anti-reflection molding 8, and a range of average surfaceroughnesses Ra has to be selected accordingly and appropriately.

In general, the greater viewing frequency a use of an anti-reflectionmolding involves, the greater anti-reflection effect the moldingrequires and it is desirable for the molding to have a small averagesurface roughness Ra. That is, a great viewing frequency heavily burdenseyes of a viewer. Little reflection increases comfort during viewing andtherefore increases resistance of eyes to fatigue. Accordingly,achievement of a great anti-reflection effect leads to prevention offatigue of eyes of viewers. Provided that the viewing frequency is high,the molding preferably has a great anti-reflection property with areflectance of not more than 0.5%, and a value of the average surfaceroughness Ra is preferably not more than 90 nm.

Anti-reflection moldings that are used in outdoor environments require agreater anti-reflection effect and desirably have smaller averagesurface roughnesses Ra in comparison with anti-reflection moldings thatare used in indoor environments. A reason why such a greatanti-reflection effect is required is as follows. It is lighter outdoorsthan indoors in the daytime, sunbeams reflected by a surface of adisplay makes the display difficult to see, and thus a greateranti-reflection effect is required outdoors. For outdoor use, thereflectance is preferably not more than 1.7%, and a value of the averagesurface roughness Ra is preferably not more than 145 nm.

On condition that an anti-reflection molding is placed and used in frontof a display, a color display requires a greater anti-reflection effectand desirably involves a smaller average surface roughness Ra of themolding in comparison with a monochrome display. If much reflection iscaused by a screen of the color display, an image on the display looksas if the image is discolored and has a low chroma. Thus, a chroma ismore important for a color screen than for a monochrome screen, and acolor screen therefore requires greater anti-reflection effect. For acolor screen, reflectance is preferably not more than 1.2% and a valueof the average surface roughness Ra is preferably not more than 130 nm.

Depending on uses of the anti-reflection molding 8, a distinction may bemade on a surface of the molding between an area where a greatanti-reflection function is particularly required and an area where alittle decrease in anti-reflection function causes no noticeable issues.FIG. 15 is a perspective view illustrating the anti-reflection molding 8that is used in a full-color liquid crystal display section of aportable telephone and that is 25 mm long and 33 mm wide, as an example.In the anti-reflection molding 8 for such a use, a central area CA is aregion a user of the portable telephone watches most carefully, in otherwords, a visual recognition area in the transparent window, andtherefore is an area that particularly requires an anti-reflectionfunction and that desirably has an average surface roughness Ra between2 and 35 nm. By contrast, a marginal area CB is a periphery of thecentral area CA and that is a margin of the liquid crystal displaysection, in other words, a peripheral visual recognition area on aperiphery of the visual recognition area in the transparent window isnot s region a user of the portable telephone watches carefully. Thearea CB therefore does not require so a high degree of ananti-reflection function, an average surface roughness Ra on the orderof 35 to 85 nm causes no particular issues, and thus time and effort forprocess can be saved with regard to the marginal area CB in comparisonwith the central area CA, so that a cost as a whole can be reduced.

The smaller a radius R of curvature of a surface shape of theanti-reflection molding 8, the lower a degree of necessity for ananti-reflection function. In addition, difficulty in productionincreases, for example, in that it is made difficult to perform aprocess of polishing a surface of a metal mold 10 for molding todecrease a surface roughness thereof and in that it is made difficult toform the anti-reflection layer 5 with a uniform thickness. In an areawhere the radius R of curvature of the surface shape of theanti-reflection molding 8 is small, accordingly, the average surfaceroughness Ra is preferably decreased, for example, so as to be on theorder of 85 to 140 nm. Unless any particular issues occur, theanti-reflection function therein may be omitted thoroughly. Providedthat the surface shape of the anti-reflection molding 8 shown in FIG. 15has a sectional shape shown in FIG. 16, for example, there is littlepossibility that a user of the portable telephone may carefully watchextremely small area CB having a radius R of curvature of smaller than40 mm, and it is difficult to provide the area with a high degree of ananti-reflection function.

Herein, “average surface roughness Ra” refers to an average surfaceroughness Ra that can be determined, as shown in FIG. 9, by obtainmentof a mean line from a cross-sectional profile curve of a surface of amolding and with use of Gaussian filter (a roughness curve is obtainedby subtraction of the mean line from the cross-sectional profile curve).

For a shape of the anti-reflection molding 8, it is important that ashape of a transparent window as a surface requiring an anti-reflectioneffect is configured so as to have a curved surface having a radius ofcurvature of not less than 40 mm or a flat surface.

A test was conducted on an order on (equal to) or above which flatnessof shapes of moldings has to be for formation of the anti-reflectionlayer 5 with a uniform thickness and, as shown in Table 3, it was foundthat at least a surface thereof has to be set so as to be a curvedsurface having a radius of curvature of not less than 40 mm. It was alsofound that a curved surface with a radius of curvature of not less than60 mm is preferably provided. As shown in FIG. 12, anti-reflectionmoldings 8 were made by production of semi-cylindrical moldings havingradii of curvature of between 30 and 300 mm and by subsequent formationthereon of anti-reflection layers 5 made of MgF, mean reflectances ofthe moldings at 550 nm were measured, and the mean reflectances of notmore than 3% were evaluated as being satisfactory, while the meanreflectances of not more than 1% were evaluated as being extremelysatisfactory.

In formation of the anti-reflection layer 5 by application of painthaving a low viscosity, such a configuration as described above canprevent flow and accumulation of the paint from a high position to a lowposition, and thus can prevent unevenness in thickness of theanti-reflection layer 5. In formation of the anti-reflection layer 5 byperforming an evaporation method, such a configuration can preventvariation with place in a quantity of deposit of deposition vapor perunit area, and thus can prevent unevenness in thickness of theanti-reflection layer 5.

Herein, “radius of curvature” refers to a radius of a circle obtained bydetermination of an arc that most approximates the mean line found bythe roughness measuring apparatus described above and then by extensionof the arc (see FIG. 9). Provided that values of radius of curvaturegreatly vary with measuring areas, a mean value of the values is used.

The surface of the anti-reflection molding 8 desirably has a hard-coatproperty and, therefore, the hard-coat layer 4 is provided desirablybefore the anti-reflection layer 5 is formed, as shown in FIG. 1A.

Among methods of forming the hard-coat layer 4 on a surface of thetransparent substrate 1 are a method in which a hard-coat agent isapplied directly onto the surface of the transparent substrate 1, amolding in-mold decorating method, and the like. In accordance with themolding in-mold decorating method, in particular, a surface of thehard-coat layer 4 can be finished so as to have a shape of a mirrorsurface or similar cavity surface that is a slightly uneven surface, andunevenness can be lessened considerably. A molding in-mold decoratingmethod in which the hard-coat layer 4 remaining unhardened orhalf-hardened on the decorating sheet 9 is made into a molding and isthereafter hardened, is further preferable because the molding caneasily be formed into the same shape as the cavity surface of the metalmold 10 and because occurrence of cracks during a molding process isthereby lessened.

In order to provide the hard-coat layer 4 or the like on the transparentsubstrate 1, it is preferable to use a molding in-mold decorating methodthat makes use of the decorating sheet 9. The molding in-mold decoratingmethod includes a molding in-mold transferring method using a transfermember 9A as the decorating sheet 9 or an inserting method using aninsert member as the decorating sheet 9.

The molding in-mold transferring method is such a method as follows. Thetransfer member 9A in which transfer layers composed of the hard-coatlayer 4 and the like have been formed on the substrate sheet 7 isinterposed into the metal mold 10 (see FIG. 3B); molten resin 1A isinjected into the metal mold 10; simultaneously with obtainment of aresin molding by cooling, the transfer member 9A is bonded onto asurface of the molding (see FIG. 6); the substrate sheet 7 issubsequently peeled off; and the transfer layers are transferred onto asurface of the resin molding to make decoration (see FIG. 7).

The inserting method is such a method as follows. The insert member 9 inwhich the hard-coat layer 4 and the like have been formed on thesubstrate sheet 7 is interposed into the metal mold 10; molten resin 1Ais injected into the metal mold 10; and, simultaneously with obtainmentof a resin molding 100 by cooling, the insert member 9 is bonded onto asurface of the molding to make decoration (see FIG. 3A).

The molding in-mold transferring method that makes use of the transfermember 9A will be described initially.

In the transfer member 9A, the transfer layers composed of the hard-coatlayer 4 and the like are provided on the substrate sheet 7 (see FIG. 6).Preferably, not all the layers that are to be formed on the transparentsubstrate 1 of the anti-reflection molding 8 are incorporated into thetransfer layers but only layer(s) suitable for formation by the moldingin-mold transferring method are the transfer layer(s), and other layersare formed separately. The hard-coat layer 4, a patterned layer, and thelike are particularly suitable for formation by the molding in-moldtransferring method.

As material of the substrate sheet 7 may be used material that is usedas a substrate sheet for a conventional transfer member, for example, aresin sheet of polypropylene resin, polyethylene resin, polyamide resin,polyester resin, acrylic resin, polyvinyl-chloride resin or the like.

Provided that peelability of the transfer layers from the substratesheet 7 is satisfactory, the hard-coat layer 4 may be provided directlyon the substrate sheet 7. In order to improve the peelability of thetransfer layers from the substrate sheet 7, a mold release layer 3 maybe formed before the hard-coat layer 4 is provided on the substratesheet 7 (see FIG. 6). By mixing silica beads or the like into the moldrelease layer 3, in particular, minute projections and depressions canbe formed on the surface of the molding when the substrate sheet 7 ispeeled off (see FIG. 7).

Subsequently, the hard-coat layer 4 is formed. The hard-coat layer 4becomes a layer that increases a surface strength of the anti-reflectionmolding 8 when the substrate sheet 7 is peeled off after the moldingin-mold transfer.

For the hard-coat layer 4 may be used thermosetting resin, resin curableby ionizing radiation such as ultraviolet ray or electron beam, or thelike. Used a lot are ultraviolet curable resins such asacrylic-urethane-based one.

Ultraviolet curable resins include ultraviolet curable acrylic urethaneresin, ultraviolet curable polyester acrylate resin, and ultravioletcurable epoxy acrylate resin and are used with a photoinitiator. Forexample, ultraviolet curable acrylic urethane resin is obtained byreaction of polyester polyol with isocyanate monomer or prepolymer andby reaction of a resultant product with acrylate or methacrylate monomerhaving hydroxyl groups. As the photoinitiator may be used benzophenones,acetophenones, anthraquinone derivatives or the like singly or incombination. For improving formation of a coating, thermoplastic acrylicresin or the like may appropriately be selected and blended withultraviolet curable resin.

Among methods of forming the hard-coat layer 4 are coating such asgravure coating, roll coating, and comma coating, and a printing processsuch as gravure and screen printing.

As occasion demands, a pattern layer 120 may be formed (see FIG. 1C).The pattern layer 120 is a layer for decorating the anti-reflectionmolding 8. The pattern layer 120 is formed on the hard-coat layer 4. Inordinary cases, the pattern layer 120 is formed as a print layer. Asmaterial of the print layer is preferably used colored ink that containsas binder such resin as polyvinyl resin, polyamide resin, polyesterresin, acrylic resin, polyurethane resin, polyvinyl acetal resin,polyesterurethane resin, cellulose ester resin, and alkyd resin and thatcontains, as a coloring agent, pigment or dye with an appropriate color.As methods of forming the print layer, a conventional printing processsuch as offset printing, gravure, screen printing or the like ispreferably employed. In ordinary cases, the print layer is partiallyprovided so as to be shaped like a frame, a letter, or the like in apattern excluding the transparent window.

The pattern layer 120 may be composed of a metal thin film layer or acombination of a print layer and a metal thin film layer. The metal thinfilm layer is intended for expressing metallic luster in the patternlayer 120 and is formed by performing vacuum deposition, a sputteringtechnique, ion plating, plating, or the like. Metal such as aluminum,nickel, gold, platinum, chromium, iron, copper, tin, indium, silver,titanium, lead, and zinc; or an alloy or compound of these metals isused in accordance with a desired color of metallic luster that is to beexpressed. In ordinary cases, the metal thin film layer is formedpartially. When the metal thin film layer is provided, a pre-anchorlayer and/or a post-anchor layer may be provided for improving adhesionto other layer(s).

An adhesive layer 2 is preferably formed for bonding the above-mentionedlayers onto the transparent substrate 1 (see FIGS. 6, 7, and 8). For theadhesive layer 2 is appropriately used a heat-sensitive orpressure-sensitive resin suitable for material of the transparentsubstrate 1.

Provided that the material of the transparent substrate 1 is acrylicresin, for example, acrylic resin is preferably used. Provided that thematerial of the transparent substrate 1 is polyphenylene oxidepolystyrene resin, polycarbonate resin, or polystyrene blend resin,preferably used is acrylic resin, polystyrene resin, polyamide resin, orthe like that has an affinity for the above resins. Provided that thematerial of the transparent substrate 1 is polypropylene resin, it ispossible to use chlorinated polyolefin resin, chlorinated ethylene vinylacetate copolymer resin, cyclized rubber, or coumarone-indene resin.Among methods of forming the adhesive layer 2 are coating such asgravure coating, roll coating, or comma coating; or a printing processsuch as gravure or screen printing.

A configuration of the transfer layers is not limited to theabove-mentioned manner. With use of material of the pattern layer thatis excellent in terms of adhesiveness with respect to the transparentsubstrate 1, for example, the adhesive layer 2 may be omitted.

With use of such an anti-reflection transfer member configured asdescribed above, use of a transfer process may be made so that theanti-reflection molding 8 can be obtained easily.

A side of the anti-reflection transfer member having the adhesive layer2 is initially brought into intimate contact with a surface of thetransparent substrate 1. With use of a transferring machine such as rolltransferring machine, and an up-down transferring machine that isprovided with a heat-resistant-rubber-like elastic body of siliconerubber or the like, subsequently, heat and pressure are applied from aside of the anti-reflection transfer member having the substrate sheet 7through the heat-resistant-rubber-like elastic body provided with acondition of a temperature on the order of 80 to 260° C., and of apressure on the order of 490 to 1960 Pa. By this process, the adhesivelayer 2 is bonded onto the surface of the transparent substrate 1.

Finally, the substrate sheet 7 is peeled off after being cooled,exfoliation (peeling) is then caused at an interface surface between thesubstrate sheet 7 and the hard-coat layer 4, and the transfer iscompleted. Provided that the mold release layer 3 has been provided onthe substrate sheet 7, peeling the substrate sheet 7 causes exfoliationat an interface surface between the mold release layer 3 and thehard-coat layer 4 and completes the transfer (see FIGS. 7 and 8).

There will now be described processes of performing the molding in-moldtransferring method by injection molding with use of the above-mentionedanti-reflection transfer member.

There is used the metal mold 10 for molding that has a curved surfacewith a radius of curvature of not less than 40 mm, or a flat surface, ina part of the cavity surface 10A corresponding to the transparentwindow. As material of the metal mold 10 may be used structural rolledsteel, carbon steels for machine structural use, carbon tool steels,alloy tool steels, high-speed steel, high-carbon chromium steel, bearingsteels, nickel-chromium-molybdenum steel, chromium-molybdenum steel,aluminum-chromium-molybdenum steel, or the like. The cavity 10B of themetal mold 10 may be formed by performing a machining method such asmilling, cold hobbing, a Shaw process, a pressure forging process,electroforming, an electric discharge machining process, an etchmachining process, or numerically controlled machining. The cavitysurface may be polished with use of file cutting, sandpaper, powderemery, steel wool, rubber grindstone, felt buff, or the like so as to befinished with a specified surface roughness.

In order to vary surface roughnesses of the cavity surface 10A accordingto areas, it is preferable that methods and degrees of polishing duringthe finish process are selected appropriately. For example, an overallarea may be polished with slightly coarse sandpaper, and a specifiedarea may subsequently be polished again with fine sandpaper, so that twoareas having different surface roughnesses may be formed in the cavitysurface 10A. As shown in FIG. 17, alternatively, an insert 10 f having ametal mold surface polished carefully may be inserted into a metal mold10 d having a rough metal mold surface, and finish fitting may beperformed so that two areas having different surface roughnesses may beformed in the cavity surface 10A. For example, the area of the cavitysurface 10A polished again with fine sandpaper, or the insert 10 fhaving the metal mold surface polished carefully, may be used in orderthat the central area CA of the anti-reflection molding 8, i.e., thevisual recognition area in the transparent window, may be made and mayhave an average surface roughness Ra of between 2 and 35 nm. The area ofthe cavity surface 10A polished only with slightly coarse sandpaper, orthe metal mold 10 d having the rough metal mold surface, may be used inorder that the marginal area CB which is the periphery of the centralarea CA and is a margin of the liquid crystal display section, i.e., aperipheral visual recognition area on the periphery of the visualrecognition area in the transparent window, may be made and may have anaverage surface roughness Ra on the order of 35 to 85 nm.

In the molding in-mold transferring method, initially, the transfermember 9A that is the decorating sheet 9, is delivered into the metalmold 10 for molding. During this step, sheet-like transfer members 9Amay be delivered one by one or required portions of a long-sizedtransfer member 9A may be delivered intermittently. In the case that thelong-sized transfer member 9A is used, a feeder having a positioningdevice is preferably used so that a pattern layer 120 of the transfermember 9A and the metal mold 10 may be in register. When the transfermember 9A is delivered intermittently, it is convenient to hold thetransfer member 9A by a movable mold and a stationary mold afterdetection of a position of the transfer member 9A by a sensor, in thatthe transfer member 9A can be held in the same position at any time andin that mis-registration of the pattern layer 120 is prevented.

After closure of the metal mold 10, molten resin 1A is injected from agate into the metal mold 10 to fill the mold, an object of transfer isformed and, simultaneously with this formation, the transfer member 9Ais made to adhere onto a surface of the object.

As resin that may be used for the transparent substrate 1 may be namedgeneral-purpose resin such as polystyrene resin, polyolefin resin, ABSresin, AS resin, or AN resin. There also may be used general-purposeengineering resin such as polyphenylene oxide polystyrene resin,polycarbonate resin, polyacetal resin, acrylic resin, polycarbonatedenatured polyphenylene ether resin, polybutylene terephthalate resin,or ultragiant molecular weight polyethylene resin; or super engineeringresin such as polysulfone resin, polyphenylene sulfide resin,polyphenylene oxide resin, polyarylate resin, polyetherimide resin,polyimide resin, liquid crystalline polyester resin, or polyallylheat-resistant resin.

The transparent substrate 1 may have entirely a tabular shape or a shapeincluding a two-dimensional or three-dimensional curved surface, as longas the substrate 1 has a concave curved surface having a radius ofcurvature of not less than 40 mm, or a flat surface, in the transparentwindow.

A resin molding as the object of transfer is cooled, the metal mold 10is thereafter opened, and the resin molding is removed therefrom.Finally, the substrate sheet 7 of the transfer member 9A is peeled off(see FIG. 7). Thus only the transfer layers can be transferred to themolding (see FIG. 8).

Hereinbelow, the inserting method using the insert member 9 will bedescribed.

The insert member 9 is preferably obtained by such a method as follows.

For the insert member 9, the hard-coat layer 4, the pattern layer, andthe like are provided on the substrate sheet 7 (see FIG. 2).

Preferably used is the substrate sheet 7 similar to that of the transfermember. The hard-coat layer 4, the pattern layer, the adhesive layer 2,and the like can be formed in a manner similar to those of the transfermember.

The inserting method in which the substrate sheet 7 is neither peeledoff nor removed allows formation of the hard-coat layer 4 on one surfaceof the substrate sheet 7 and formation of the pattern layer and theadhesive layer 2 on another surface, or allows formation of thehard-coat layer 4 and the pattern layer on one surface and formation ofthe adhesive layer 2 on the other surface.

Preferably, not all the layers that are to be formed on the transparentsubstrate 1 are formed by the inserting method, but only layers suitablefor formation by the inserting method are formed by the molding in-molddecorating method, and other layer(s) are formed separately.

Hereinbelow, a method of using the insert member 9 will be described.

There is used the metal mold 10 that has a curved surface having aradius of curvature of not less than 40 mm, or a flat surface, in anarea of the cavity surface 10A corresponding to the transparent window.As for the insert member 9, minute projections and depressions cannot beformed by the mold release layer 3, and therefore, minute projectionsand depressions are preferably formed on the area of the cavity surface10A of the metal mold 10 corresponding to the transparent window (seeFIG. 3A and FIG. 11). In particular, an average surface roughness Ra inthe area of the cavity surface 10A corresponding to the transparentwindow is preferably between 2.0 and 170 nm, because an average surfaceroughness Ra of the interface between the anti-reflection layer 5 thatis to be formed later and the transparent window can be set between 2.0and 150 nm.

Initially, the insert member 9 that is the decorating sheet 9 isdelivered into the metal mold 10 (see FIGS. 3A and 3B). In this step,sheet-like insert members 9 are preferably delivered one by one.Provided that a molding shape is three-dimensional, the insert member 9may be heated and softened by a heat source and may be brought intointimate contact with the cavity surface 10A by vacuum suction. Then themold is clamped and molten resin 1A is injected from the gate (see FIG.4). When the mold is opened, a molding in which the insert member 9 andthe molding resin 1A are integrated is obtained (see FIG. 5).

In this manner, the insert member 9 and the molding resin 1A areintegrated to form a molding having a transparent window that has anaverage surface roughness Ra of between 2.0 and 150 nm, and that has aconcave curved surface with a radius of curvature of not less than 40mm, or a flat surface (see FIG. 5).

After the hard-coat layer 4 is formed with use of the decorating sheet 9of the transfer member or the insert member, the anti-reflection layer 5is formed at least on the transparent window (see FIGS. 1A and 1B).Reflection from the transparent substrate 1 can be prevented byprovision of the anti-reflection layer 5.

As material of the anti-reflection layer 5 may be used: a vapordeposited layer of a metal compound such as Al₂O₃, ZnO₂, or MgF₂; avapor deposited layer in which a metal compound having a low index ofrefraction such as SiO₂ or MgF₂ and a metal compound having a high indexof refraction such as ZnO₂ or TiO₂ are laminated; a resin coating layercomposed of fluoropolymer, silicon oxide gel, or the like; or the like.A combination of these materials may be used.

Among methods of manufacturing the anti-reflection layer 5 are a vacuumdeposition method, a sputtering technique, ion plating, and the like.There also is a method in which the anti-reflection layer 5 is obtainedby application of an organic metal compound such as metal alcoholate ormetal chelate onto the transparent substrate 1 by performing a dippingmethod, a printing process, a coating process, or the like, andsubsequent formation of a metal oxide film by performingphotoirradiation or drying.

The anti-reflection layer 5 may be composed of only one layer having alow index of refraction, or may be composed of a plurality ofanti-reflection layers that will be described later (see FIG. 23) andthat is a complex layer of layer(s) with a low index of refraction andlayer(s) with a high index of refraction. Use of the complex layer mayimprove an anti-reflection property. In order to cancel an increase innumber of man-hours that may result from use of the complex layer, it isextremely efficient to form the anti-reflection layer 5 by performing aroll-to-roll continuous coating process. For such a transfer member asin the embodiment, roll-to-roll continuous production can be achieved.Herein, “low index of refraction” and “high index of refraction” aredefined by a result of comparison with an index of refraction that alayer residing under those layers has. As for the anti-reflection layer5 composed of one layer, for example, a basis of the comparison is anindex of refraction that the hard-coat layer 1 has. As for theanti-reflection layer 5 having the complex layer, a basis of thecomparison is an index of refraction of a layer that resides directlyunder each layer constituting the anti-reflection layer 5.

Preferably, a film thickness of the anti-reflection layer 5 isappropriately selected so as to satisfy a general expression nd=λ/4, ora general expression nd=3λ/4 (wherein n is an index of refraction of asubstance with a low index of refraction, d is a film thickness of thesubstance with the low index of refraction, and λ is a low reflectioncentral wavelength). In ordinary cases, the thickness of theanti-reflection layer 5 is in a range of 0.01 to 2 μm.

As occasion demands, an anti-fouling layer 190 may be provided on theanti-reflection layer 5 (see alternate long and short dash lines inFIGS. 1A, 1B, and 1C). The anti-fouling layer 190 is a layer that isprovided on the anti-reflection layer 5 for preventing contamination ofthe anti-reflection molding 8, and that is composed of material havingwater-repellency and oil-repellency. For the anti-fouling layer 190 ispreferably used a surface active agent having fluorine in end groups, orthe like. The anti-fouling layer 190 is preferably provided byperforming a coating process, a dipping method, a vacuum depositionmethod, or the like. It is preferable for a thickness of theanti-fouling layer 190 to be as small as possible. A reason for this isthat a light transmittance of the anti-reflection molding 8 decreaseswith increase in the thickness of the anti-fouling layer 190.

Hereinbelow, more concrete examples of the first embodiment will bedescribed as working examples.

WORKING EXAMPLES 1 THROUGH 9

Polycarbonate film with a thickness of 50 μm was used as a substratesheet, a hard-coat layer with a thickness of 4 μm was formed thereonwith use of urethane acrylate resin, and an insert member was therebyobtained (see FIG. 2).

Then various injection metal molds were produced that had averagesurface roughnesses Ra of between 0.002 and 0.19 μm in an areacorresponding to a transparent window, the insert member was loaded intoeach metal mold, the metal molds were closed, acrylic resin wasinjected, and obtained were moldings that had unevenness of variousdegrees on surfaces of the hard-coat layers.

The moldings had a shape of a flat plate that measured 60 mm by 60 mm by1.5 mm.

An anti-reflection layer of magnesium fluoride with a thickness of about0.1 μm was then formed on the hard-coat layer of each molding andanti-reflection moldings were thereby obtained (see FIG. 11).

In measurement of reflectances of the anti-reflection moldings thusobtained, working examples 1 through 6 exhibited an anti-reflectionproperty of high degrees and, in particular, the working examples 1through 5 were highly excellent. Working examples 7 and 8 exhibited ananti-reflection effect that was of some degree but considerably inferiorto that of the working examples 1 through 6. Working example 9 hadlittle anti-reflection effect.

TABLE 1 Surface Surface roughness Thickness roughness of of anti- ofmetal hardcoat reflection Reflectance mold (nm) layer (nm) layer (nm)(%) Evaluation Working 2 2 100 ± 0  0.2 ⊚ Example 1 Working 10 9 100 ±0  0.2 ⊚ Example 2 Working 30 28 90 ± 0  0.2 ⊚ Example 3 Working 50 44100 ± 10  0.3 ⊚ Example 4 Working 80 71 110 ± 10  0.4 ⊚ Example 5Working 110 100 100 ± 10  0.9 ∘ Example 6 Working 150 130 100 ± 20  2.1Δ Example 7 Working 170 150 110 ± 20  3.1 Δ Example 8 Working 190 180100 ± 50  5.4 x Example 9

Herein, evaluation “⊚” designates “excellent”, “O” designates “good”,“Δ” designates “fair”, and “x” designates “failure”.

WORKING EXAMPLES 10 THROUGH 18

Polyester film with a thickness of 38 μm was used as a substrate sheet,a mold release layer with an average surface roughness Ra of between0.002 and 0.19 μm was formed thereon with use of melamine resin in whicheight parts by weight of silica beads having particle sizes of between0.4 and 8 μm were added to 100 parts of main ingredient, a hard-coatlayer with a thickness of 4 μm was formed thereon with use of urethaneacrylate resin, an adhesive layer was formed thereon with use of acrylicresin, and various transfer members were thereby obtained (see FIG. 2).

Each transfer member was placed on a molding of acrylic resin having ashape of a flat plate that measured 60 mm by 60 mm by 1.5 mm, a pressurewas applied thereto from a backside by a heating roller, the substratesheet was peeled off, and obtained were moldings of which surfaces werelaminated with the hard-coat layers having unevenness of variousdegrees.

Subsequently, an anti-reflection layer of magnesium fluoride with athickness of about 0.1 μm was then formed on the hard-coat layer of eachmolding and various anti-reflection moldings were thereby obtained.

In measurement of reflectances of the anti-reflection moldings thusobtained, working examples 10 through 15 exhibited an anti-reflectionproperty of high degrees and, in particular, the working examples 10through 14 were highly excellent. Working examples 16 and 17 exhibitedan anti-reflection effect that was of some degree but considerablyinferior to that of the working examples 10 through 15. Working example18 had little anti-reflection effect.

TABLE 2 Surface Surface Particle roughness roughness Thickness Re- sizeof of mold of of anti- flec- beads release hardcoat reflection tanceEvalu- (μm) layer (nm) layer (nm) layer (nm) (%) ation Working No 10 10100 ± 0  0.2 ⊚ Example addition 10 Working 0.4 10 10 100 ± 0  0.2 ⊚Example 11 Working 0.6 30 30  90 ± 0  0.2 ⊚ Example 12 Working 1.0 50 50100 ± 0  0.3 ⊚ Example 13 Working 2.0 80 70 110 ± 10 0.4 ⊚ Example 14Working 3.0 110 100 100 ± 10 0.9 ∘ Example 15 Working 5.0 140 130 100 ±20 2.1 Δ Example 16 Working 6.0 170 150 110 ± 30 3.1 Δ Example 17Working 8.0 190 180 100 ± 60 5.4 x Example 18 (Working Examples 19through 27)

The insert member used in the working example 1 was used and loaded intoan injection metal mold (see FIG. 10), the metal mold was closed,acrylic resin was injected, and manufactured were a molding having ashape of a flat plate that measured 60 mm by 60 mm by 1.5 mm, andmoldings having semicylindrical shapes with radii of curvature ofbetween 30 and 300 mm (see FIG. 12). Cavity surfaces of the injectionmetal molds were designed so that average surface roughnesses Ra of allthe moldings were on the order of 0.01 μm.

Subsequently, anti-reflection layers of magnesium fluoride with athickness of about 0.1 μm were formed on hard-coat layers of themoldings, and anti-reflection moldings were thereby obtained.

TABLE 3 Thickness of anti- Mean Shape of reflection reflectance moldinglayer (%) (%) Evaluation Working Flat 110 ± 0 0.2 ⊚ Example plate 19 60mm by 60 mm Working Semi-  90 ± 0 0.2 ⊚ Example cylinder 20 radius ofcurvature 300 mm Working Semi-  90 ± 0 0.2 ⊚ Example cylinder 21 radiusof curvature 180 mm Working Semi-  110 ± 10 0.3 ⊚ Example cylinder 22radius of curvature 120 mm Working Semi-  100 ± 10 0.4 ⊚ Examplecylinder 23 radius of curvature 90 mm Working Semi-  100 ± 20 0.9 ◯Example cylinder 24 radius of curvature 60 mm Working Semi-  90 ± 20 1.6Δ Example cylinder 25 radius of curvature 50 mm Working Semi-  100 ± 302.9 ⊚ Example cylinder 26 radius of curvature 40 mm Working Semi-  110 ±50 4.8 ⊚ Example cylinder 27 radius of curvature 30 mm

In measurement of reflectances of the anti-reflection moldings thusobtained, working examples 19 through 24 exhibited an anti-reflectionproperty of high degrees and, in particular, the working examples 19through 23 were highly excellent. Working examples 25 and 26 exhibitedan anti-reflection effect that was of some degree but considerablyinferior to that of the working examples 19 through 24. Working example27 had little anti-reflection effect.

The present invention adopts such configurations as described above andtherefore achieves such effects as follows.

In the method of manufacturing the anti-reflection moldings of thepresent invention, the decorating sheet having at least the hard-coatlayer formed on the substrate sheet is placed so that a side having thesubstrate sheet comes into contact with a cavity surface of the metalmold that is a curved surface having a radius of curvature of not lessthan 40 mm, or a flat surface, in an area corresponding to thetransparent window, transparent molten resin is injected into the metalmold so that an integrated body of the decorating sheet and thetransparent substrate formed of the resin is obtained, the substratesheet is subsequently peeled off so that a curved surface having aradius of curvature of not less than 40 mm and protruding on the surfaceside in the transparent window, or a flat surface, is formed with anaverage surface roughness Ra of between 2.0 and 150 nm in thetransparent window, the anti-reflection layer is subsequently formed onthe surface side of the transparent substrate, and thus anti-reflectionmoldings having an excellent anti-reflection effect and hard-coatproperty can be obtained easily.

The metal mold for the anti-reflection molding of the present inventionhas a curved surface having a radius of curvature of not less than 40mm, or a flat surface, in an area corresponding to the transparentwindow and, therefore, use of the metal mold makes it possible to easilyobtain anti-reflection moldings having an excellent anti-reflectioneffect and hard-coat property.

The anti-reflection molding of the present invention has an excellentanti-reflection effect and hard-coat property because at least theanti-reflection layer is formed on the surface of the transparentsubstrate, because an interface of the transparent window on which theanti-reflection layer is formed has an average surface roughness Ra ofbetween 2.0 and 150 nm, and because the molding has a curved surfacehaving a radius of curvature of not less than 40 mm and protruding onthe surface side, or a flat surface, in the transparent window.

Second Embodiment

A second embodiment of the present invention will be described in detailwith reference to the drawings. The second embodiment is intended forproviding an anti-reflection transfer member that facilitates formationof an anti-reflection layer with a uniform thickness.

FIG. 18 is a sectional view illustrating an anti-reflection transfermember of the second embodiment of the present invention. FIG. 19 is asectional view illustrating an anti-reflection molding manufactured withuse of the anti-reflection transfer member of the second embodiment ofthe present invention. FIG. 20 is a perspective view illustrating ananti-reflection molding manufactured with use of the anti-reflectiontransfer member of the second embodiment of the present invention. FIGS.21 and 22 are sectional views illustrating steps of manufacturing ananti-reflection molding with use of the anti-reflection transfer memberof the second embodiment of the present invention. In the secondembodiment, FIG. 15 used in the first embodiment is used also as aperspective view illustrating an anti-reflection molding manufacturedwith use of the anti-reflection transfer member of the second embodimentof the present invention. FIG. 16 is similarly used as a sectional viewillustrating the anti-reflection molding manufactured with use of theanti-reflection transfer member of the second embodiment of the presentinvention. FIG. 25 is a sectional view illustrating an anti-reflectiontransfer member of the second embodiment of the present invention.

In the drawings, reference numeral 201 denotes a substrate sheet,numeral 202 denotes an anti-reflection layer, numeral 203 denotes ahard-coat layer, numeral 204 denotes a pattern layer, numeral 205denotes an adhesive layer, numeral 206 denotes an anti-reflectiontransfer member, numeral 207 denotes a transparent substrate, numeral208 denotes an anti-fouling layer, numeral 209 denotes ananti-reflection molding, and numeral 210 denotes a metal mold.

In the anti-reflection transfer member 206 of the second embodiment ofthe present invention, at least the anti-reflection layer 202 isprovided on the substrate sheet 201, directly or with a mold releaselayer therebetween, and a surface of the substrate sheet 201 or asurface of the mold release layer has an average surface roughness Ra ofbetween 2.0 and 150 nm (see FIG. 18).

For formation of anti-reflection layers 202 with a uniform thickness,the substrate sheet 201 as a foundation is required to have asmoothness. As a result of various tests on smoothness of the substratesheet 201, as shown in Table 4, it was found that an excellentanti-reflection effect was achieved with the substrate sheet 201 havingan average surface roughness Ra of between 2.0 and 150 nm. It isextremely difficult to manufacture the substrate sheet 201 having anaverage surface roughness Ra of less than 2.0 nm. On condition that theaverage surface roughness Ra exceeds 150 nm, thicknesses of theanti-reflection layers 202 are made extremely uneven and theanti-reflection effect of the anti-reflection layers 202 is extremelydeteriorated. In order that the substrate sheet 201 may have an averagesurface roughness Ra of between 2.0 and 150 nm, the surface of thesubstrate sheet 201 is preferably smoothed by mirror press working orthe like, or a mold release layer having an excellent leveling propertyis preferably formed. Preferable average surface roughnesses Ra arebetween 5.0 and 140 nm. It may be difficult to manufacture the substratesheet 201 having an average surface roughness Ra of less than 5.0 nm. Oncondition that the average surface roughness Ra exceeds 140 nm,thicknesses of the anti-reflection layers 202 are made uneven and theanti-reflection effect of the anti-reflection layers 202 may bedeteriorated. Further preferable average surface roughnesses Ra arebetween 5.0 and 80 nm. It was found that a thickness tolerance of theanti-reflection layers 202, and a reflectance of the anti-reflectionmolding 209 manufactured with use of the anti-reflection transfer member206, were little changed even if the sheet having an average surfaceroughness Ra of not more than 35 nm was further smoothed.

In the first embodiment, an uneven interface is positioned inside afterthe anti-reflection layer 205 is provided (see FIGS. 1A through 1C). Insuch a structure, unevenness of the surface of the anti-reflection layer205 decreases with increase in a number of stacked anti-reflectionlayers 205 (see FIG. 23).

In the second embodiment, however, an average surface roughness Ra of anoutermost surface of the anti-reflection layer 202 is equal to anaverage surface roughness Ra of the surface of the mold release layer orthe substrate sheet, because transfer layers provided with theanti-reflection layers 202 are transferred onto a surface of the molding(see FIG. 24).

The anti-reflection effect is achieved by cancellation of reflectedlight by interference thereof in interfaces of the anti-reflectionlayers, and thus an anti-reflection layer that is the nearer to theoutermost surface has the greater anti-reflection effect and makesuniformity in film thickness thereof the more important.

Accordingly, an anti-reflection effect that is achieved by theanti-reflection layers provided in the first embodiment on conditionthat the surface of the hard-coat layer has an average surface roughnessRa of 150 nm is superior to an anti-reflection effect that is achievedby the anti-reflection layers provided in the second embodiment oncondition that the outermost surface of the anti-reflection layers hasan average surface roughness Ra of 150 nm, as long as materials and filmthicknesses are the same.

In order that an anti-reflection effect on the same level as an effectachieved by the anti-reflection layers provided in the first embodimentmay be achieved in the second embodiment, therefore, the unevenness hasto be decreased for increasing uniformity in thickness.

As a result of tests, 140 nm was an average surface roughness Ra of theoutermost surface of the anti-reflection layers of the second embodimentthat provided a reflectance of nearly the same value of a reflectanceachieved by the anti-reflection layers provided in the first embodimentwith the surface of the hard-coat layer having the average surfaceroughness Ra of 150 nm.

As material of the substrate sheet 201 may be used material that is usedas a substrate sheet for a conventional transfer member, for example, aresin sheet of polypropylene resin, polyethylene resin, polyamide resin,polyester resin, acrylic resin, polyvinyl-chloride resin, or the like.

Provided that peelability of the transfer layers from the substratesheet 201 is satisfactory, the anti-reflection layers 202 may beprovided directly on the substrate sheet 201. In order to improve thepeelability of the transfer layers from the substrate sheet 201, themold release layer may be formed before the anti-reflection layers 202are provided on the substrate sheet 201. The mold release layer ispeeled and removed with the substrate sheet 201 from the transfer layerswhen the substrate sheet 201 is peeled off after molding in-moldtransfer. As material of the mold release layer may be used melamineresin mold release agent, silicone resin mold release agent, fluororesinmold release agent, cellulose derivative mold release agent, urea resinmold release agent, polyolefin resin mold release agent, paraffinic moldrelease agent, complex mold release agent of those agents, or the like.Among methods of forming the mold release layer are coating such as rollcoating or spray coating; and a printing process such as gravure orscreen printing.

The anti-reflection layers 202 are formed directly on the substratesheet 201 or on the mold release layer. The anti-reflection layers 202are layers for preventing reflection from the transparent substrate 207.

As material of the anti-reflection layers 202 may be used: vapordeposited layers of metal compound such as Al₂O₃, ZnO₂, or MgF₂; vapordeposited layers in which a metal compound having a low index ofrefraction such as SiO₂ or MgF₂ and a metal compound having a high indexof refraction such as ZnO₂ or TiO₂ are laminated; resin coating layerscomposed of fluoropolymer, silicon oxide gel, or the like; or the like.A combination of these materials may be used.

Among methods of manufacturing the anti-reflection layers 202 are avacuum deposition method, a sputtering technique, ion plating, and thelike. There also is a method in which the anti-reflection layers 202 areobtained by application of an organic metal compound such as metalalcoholate or metal chelate by performing a dipping method, a printingprocess, a coating process, or the like and subsequent formation ofmetal oxide film by performing photoirradiation or drying.

The anti-reflection layers 202 may be composed of only one layer havinga low index of refraction or may be composed of complex layer(s) oflayer(s) with a low index of refraction and layer(s) with a high indexof refraction. Use of the complex layer may improve an anti-reflectionproperty. In order to cancel an increase in number of man-hours forformation of the complex layer, it is extremely efficient to form theanti-reflection layer 202 by performing a roll-to-roll continuouscoating process.

Preferably, a film thickness of the anti-reflection layers 202 isappropriately selected so as to satisfy a general expression nd=λ/4 or ageneral expression nd=3λ/4 (wherein n is an index of refraction of asubstance with a low index of refraction, d is a film thickness of thesubstance with the low index of refraction, and λ is a low reflectioncentral wavelength). In ordinary cases, the thickness of theanti-reflection layers 202 is in a range of 10 nm to 2.0 μm.

As occasion demands, the hard-coat layer 203 may be provided on theanti-reflection layer 202. In the present invention, the hard-coat layer203 refers to a layer that has a surface hardness equal to or harderthan a pencil hardness of H in measurement by a measuring method of JISK5400. The layer may be made to remain unhardened or half-hardened(softer than H) on the transfer member 206 and, after being transferred,may be hardened so as to have a pencil hardness of H or harder than H.Once the substrate sheet 201 is peeled off after molding in-moldtransfer, the hard-coat layer 203 is made a layer for increasing asurface strength of the anti-reflection molding 209.

For the hard-coat layer 203 may be used thermosetting resin, resincurable by ionizing radiation such as ultraviolet ray or electron beam,or the like. Used a lot are ultraviolet curable resins such as anacrylic-urethane-based one.

Ultraviolet curable resins include ultraviolet curable acrylic urethaneresin, ultraviolet curable polyester acrylate resin, and ultravioletcurable epoxy acrylate resin, and are used with a photoinitiator. Forexample, ultraviolet curable acrylic urethane resin is obtained byreaction of polyester polyol with isocyanate monomer or prepolymer, andby reaction of a resultant product with acrylate or methacrylate monomerhaving hydroxyl groups. As the photoinitiator may be used benzophenones,acetophenones, anthraquinone derivatives or the like, singly or incombination. For improving formation of coating, thermoplastic acrylicresin or the like may appropriately be selected and blended withultraviolet curable resins.

Among methods of forming the hard-coat layer 203 are coating such asgravure coating, roll coating, or comma coating; and a printing processsuch as gravure or screen printing.

As occasion demands, the pattern layer 204 may be formed. The patternlayer 204 is a layer for decorating the anti-reflection molding 209.Provided that the anti-reflection molding 209 is a cover component for adisplay section, the pattern layer 204 is partially provided so as to beshaped like a frame, a letter, or the like in a pattern excluding thetransparent window, in ordinary cases. The pattern layer 204 is formedon the hard-coat layer 203. In normal times, the pattern layer 204 isformed as a print layer. As material of the print layer is preferablyused colored ink that contains as binder such resin as polyvinyl resin,polyamide resin, polyester resin, acrylic resin, polyurethane resin,polyvinyl acetal resin, polyesterurethane resin, cellulose ester resin,or alkyd resin and that contains, as coloring agent, pigment or dye thathas an appropriate color. As methods of forming the print layer, aconventional printing process such as offset printing, gravure or screenprinting; or the like is employed preferably.

The pattern layer 204 may be composed of a metal thin film layer or acombination of a print layer and a metal thin film layer. The metal thinfilm layer is intended for expressing metallic luster in the patternlayer 204 and is formed by performing a vacuum deposition method,sputtering technique, ion plating, plating, or the like. Metal such asaluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium,silver, titanium, lead, or zinc; or an alloy or compound of these metalsis used in accordance with a desired color of metallic luster that is tobe expressed. In ordinary cases, the metal thin film layer is formedpartially. When the metal thin film layer is provided, a pre-anchorlayer and/or a post-anchor layer may be provided for improving adhesionto other layer(s).

Adhesive layers 205 are preferably formed for bonding theabove-mentioned layers onto the transparent substrate 207. For theadhesive layers 205 are appropriately used heat-sensitive orpressure-sensitive resin suitable for material of the transparentsubstrate 207.

Provided that the material of the transparent substrate 207 is acrylicresin, for example, acrylic resin is preferably used for the adhesivelayer. Provided that the material of the transparent substrate 207 ispolyphenylene oxide polystyrene resin, polycarbonate resin, orpolystyrene blend resin, preferably used is acrylic resin, polystyreneresin, polyamide resin, or the like that has an affinity for the aboveresins. Provided that the material of the transparent substrate 207 ispolypropylene resin, it is possible to use chlorinated polyolefin resin,chlorinated ethylene vinyl acetate copolymer resin, cyclized rubber, orcoumarone-indene resin. Among methods of forming the adhesive layer 205are coating such as gravure coating, roll coating, or comma coating; anda printing process such as gravure or screen printing.

A configuration of the transfer layer(s) is not limited to theabove-mentioned manner. With use of material of the pattern layer 204that is excellent in terms of adhesiveness with respect to thetransparent substrate 207, for example, the adhesive layer 205 may beomitted.

Depending on uses of the anti-reflection molding 208, a distinction maybe made on a surface of the molding between an area where a greatanti-reflection function is particularly required and an area where alittle decrease in anti-reflection function causes no noticeable issues.FIG. 15 is the perspective view illustrating an anti-reflection molding208 that is used in a full-color liquid crystal display section of aportable telephone and that is 25 mm long and 33 mm wide. In theanti-reflection molding 208 for such a use, a central area CA is aregion a user of the portable telephone watches most carefully, in otherwords, a visual recognition area in the transparent window, andtherefore is an area that particularly requires an anti-reflectionfunction and that desirably has an average surface roughness Ra ofbetween 2 and 35 nm. By contrast, a marginal area CB that is a peripheryof the central area CA and is a margin of the liquid crystal displaysection, in other words, a peripheral visual recognition area onperiphery of the visual recognition area in the transparent window isnot the region a user of the portable telephone watches carefully, thearea CB therefore does not require so high degree of anti-reflectionfunction, and an average surface roughness Ra on the order of 35 to 85nm causes no particular issues.

The smaller a radius R of curvature of a surface shape of theanti-reflection molding 208, the lower a degree of necessity foranti-reflection function. In an area where the radius R of curvature ofthe surface shape of the anti-reflection molding 208 is small,accordingly, the average surface roughness Ra is preferably decreased,for example, so as to be on the order of 85 to 140 nm. Unless anyparticular issues occur, an anti-reflection function may be omittedtherein thoroughly. Provided that the surface shape of theanti-reflection molding 208 shown in FIG. 15 has the sectional shapeshown in FIG. 16, for example, there is little possibility that a userof the portable telephone may carefully watch the extremely small areaCB having a radius R of curvature of smaller than 40 mm.

Accordingly, two or more mold release layers 220 having differentaverage surface roughnesses Ra may be formed in a pattern. On conditionthat an average surface roughness Ra of a mold release layer 220 has alarge value, peeling at an interface between the mold release layer andthe anti-reflection layer is made difficult, and faulty peeling called“foil fin” might be caused. In the vicinity of the marginal area CB, asshown in FIG. 25, the average surface roughness Ra may be increased tosuch a limit that vanishment of the anti-reflection effect is avoidedand thicknesses of a mold release layer 220L may be partially increased.Thus, thicknesses of the transfer layers can be made relatively smalland occurrence of foil fin in the marginal area CB can be prevented. Theabove formation is preferably made so that a mold release layer 220Hhaving a small average surface roughness Ra is positioned on the centralarea CA.

Anti-reflection layers 202 made of different materials may be formed ina pattern (see FIG. 25). In the marginal area CB having a small radius Rof curvature that is provided with the anti-reflection layers 202, theanti-reflection layers 202 composed of a metal compound such asmagnesium fluoride having no tensibility may suffer cracks. A low-degreeanti-reflection layer 202L composed of resin material such asfluororesin, acrylic resin, or urethane resin is preferably formedpartially in a pattern in the marginal area CB and high-degreeanti-reflection layers 202H composed of a metal compound are preferablyformed partially in a pattern in the central area CA. That is becausethe low-degree anti-reflection layer 202L composed of resin material hasa low degree of an anti-reflection effect but has a considerably lowrisk of causing cracks.

The above configurations may be combined. That is, as shown in FIG. 25,in the central area CA are preferably formed the mold release layer 220Hhaving an average surface roughness Ra on the order of 5 nm that is assmall as possible and the high-degree anti-reflection layers 202Hcomposed of a plurality of metal compound layers and having a highdegree of an anti-reflection effect, and in the marginal area CB arepreferably formed the mold release layer 220L having an average surfaceroughness Ra on the order of 110 to 140 nm in a range that ensures aminimum anti-reflection effect and the low-degree anti-reflection layer202L composed of fluororesin that has excellent flexibility.

Alternatively, the mold release layers may be formed neither in thecentral area CA nor in the marginal area CB, an average surfaceroughness Ra of the substrate sheet in the central area a may be set at5 nm that is as small as possible, and a surface roughness Ra of thesubstrate sheet in the marginal area CB may be set on the order of 110to 140 nm.

Alternatively, a configuration may be employed that makes use of averagesurface roughnesses Ra of the substrate sheet and average surfaceroughness Ra of the mold release layers, in combination.

With use of the anti-reflection transfer member 206 configured asdescribed above, use of a transfer process may be made so that theanti-reflection molding 209 is obtained easily.

A side of the anti-reflection transfer member 206 having the adhesivelayer 205 is initially brought into intimate contact with a surface ofthe transparent substrate 207. With use of a transferring machine suchas a roll transferring machine or up-down transferring machine providedwith a heat-resistant-rubber-like elastic body of silicone rubber or thelike, subsequently, heat and pressure are applied from a side of theanti-reflection transfer member 206 having the substrate sheet 201through the heat-resistant-rubber-like elastic body provided with acondition of a temperature on the order of 80 to 260° C. and of apressure on the order of 490 to 1960 Pa. By this process, the adhesivelayer 205 is bonded onto the surface of the transparent substrate 207.

Finally, the substrate sheet 201 is peeled off after being cooled,exfoliation is then caused at an interface surface between the substratesheet 201 and the anti-reflection layers 202, and the transfer iscompleted. On condition that the mold release layer is provided on thesubstrate sheet 201, peeling the substrate sheet 201 causes exfoliationat an interface surface between the mold release layer and theanti-reflection layers 202 and completes the transfer. Thus theanti-reflection molding 209 is obtained.

There will now be described a method of obtaining the anti-reflectionmolding 209 by making use of the molding in-mold transferring method byinjection molding with use of the above-mentioned anti-reflectiontransfer member 206.

As the metal mold 210 for molding, a metal mold for use in injectionmolding is used.

The anti-reflection transfer member 206 is initially delivered into themetal mold 210 for molding (see FIG. 21). In this step, sheet-liketransfer members 206 may be delivered one by one or required portions ofa long-sized transfer member 206 may be delivered intermittently. In thecase that the long-sized transfer member 206 is used, a feeder having apositioning device is preferably used so that the pattern layer 204 ofthe transfer member 206 and the metal mold 210 for molding may be inregister. When the transfer member 206 is delivered intermittently, itis convenient to hold the transfer member 206 by a movable mold and astationary mold after detection of a position of the transfer member 206by a sensor, in that the transfer member 206 can be held in the sameposition at any time and in that mis-registration of the pattern layer204 is prevented.

After closure of the metal mold 210 for molding, molten resin isinjected from a gate into the metal mold 210 to fill the mold, an objectof transfer is formed and, simultaneously with the formation, thetransfer member 206 is made to adhere onto a surface of the object (seeFIG. 22).

As resin that may be used for the transparent substrate 207 may be namedgeneral-purpose resins such as polystyrene resin, polyolefin resin, ABSresin, AS resin, or AN resin. There also may be used general-purposeengineering resin such as polyphenylene oxide polystyrene resin,polycarbonate resin, polyacetal resin, acrylic resin, polycarbonatedenatured polyphenylene ether resin, polybutylene terephthalate resin,or ultragiant molecular weight polyethylene resin; or super engineeringresin such as polysulfone resin, polyphenylene sulfide resin,polyphenylene oxide resin, polyarylate resin, polyetherimide resin,polyimide resin, liquid crystalline polyester resin, or polyallylheat-resistant resin. Those molding resins may be mixed with a lightdiffusing agent composed of silica beads, acrylic beads, or the like;and the like.

The transparent substrate 207 may have a tabular shape or a shapeincluding a two-dimensional or three-dimensional curved surface.

A resin molding as the object of transfer is cooled, the metal mold 210for molding is thereafter opened, and the resin molding is removed.Finally, the substrate sheet 201 of the transfer member 206 is peeledoff. Thus, only the transfer layers are transferred to the molding (seeFIGS. 19 and 3).

As occasion demands, the anti-fouling layer 208 may be provided. Theanti-fouling layer 208 is a layer that is provided on theanti-reflection layers 202 to prevent contamination of theanti-reflection molding 209, and that is composed of material havingwater-repellency and oil-repellency. For the anti-fouling layer 208 ispreferably used a surface active agent having fluorine in end groups, orthe like. The anti-fouling layer 208 is preferably provided byperforming a coating process, dipping method, vacuum deposition method,or the like. It is preferable for a thickness of the anti-fouling layer208 to be as small as possible. That is because a light transmittance ofthe anti-reflection molding 209 decreases with increase in the thicknessof the anti-fouling layer 208.

In the present invention, as described above, on the substrate sheet 201that is excellent in terms of smoothness, the anti-reflection layers 202are formed, directly or with the mold release layer therebetween; otherlayers such as the hard-coat layer 203 are thereafter formed; and thusthe anti-reflection layers 202 that have excellent uniformity in termsof thickness can be formed regardless of unevenness of other layers suchas the hard-coat layer 203.

Hereinbelow, more concrete examples of the second embodiment will bedescribed as working examples.

Polyethylene terephthalate resin films with various average surfaceroughnesses Ra shown in Table 4 were used as substrate sheets, each filmwas coated with melamine resin so that a mold release layer was formed,magnesium fluoride was then deposited thereon to form an anti-reflectionlayer with a thickness of about 100 nm, a hard-coat layer with athickness of 4 μm was then formed with use of urethane acrylate resinblended with 5% light diffusion agent, an adhesive layer was then formedwith use of acrylic resin, and anti-reflection transfer members wereobtained.

Polycarbonate film with a thickness of 50 μm was used as a transparentsubstrate, was layered on each anti-reflection transfer member, and wasbonded with heat and pressure applied from a side having the substratesheet by a roll transferring machine, then the substrate sheet waspeeled off and was removed with the mold release layer, and obtainedwere anti-reflection moldings that were anti-reflection sheets fordisplay sections of a personal computer.

TABLE 4 Surface Roughness Thickness of of anti- Re- Substrate substrateeflection flectance sheet sheet (μm) layer (μm) (%) Evaluation Working50 μm thick 0.005 0.09 ± 0.2 ⊚ Example PET film 0.00 31 mirror- pressedWorking 50 μm thick 0.012 0.11 ± 0.2 ⊚ Example PET film 0.00 32 (TOYOBOA4100) Working 25 μm thick 0.035 0.10 ± 0.2 ⊚ Example PET film 0.00 33(TOYOBO E5001) Working 25 μm thick 0.052 0.11 ± 0.4 ⊚ Example PET film0.01 34 (TOYOBO E5007) Working Film of 0.080 0.10 ± 0.5 ⊚ ExampleWorking 0.02 35 Example 34 coated with melamine resin Working Melamine0.110 0.09 ± 1.0 ∘ Example resin 0.03 36 of Working Example 35containing 5% matting agent Working Melamine 0.140 0.11 ± 2.1 Δ Exampleresin 0.04 37 of Working Example 35 containing 10% matting agent WorkingMelamine 0.190 0.10 ± 5.1 x Example resin 0.05 38 of Working Example 35containing 20% matting agent

Herein, evaluation “⊚” designates “excellent”, “O” designates “good”,“Δ” designates “fair”, and “x” designates “failure”.

In measurement of reflectances of the anti-reflection moldings thusobtained, working examples 31 through 35 proved to be highly excellentanti-reflection sheets that had an anti-reflection property of highdegree and a hard-coat property. Working example 36 had a littledegraded anti-reflection property in comparison with that of the workingexamples 31 through 35 but had performance sufficient and required forsome usage, as shown in FIG. 14. Working example 37 was a littleinferior in terms of an anti-reflection effect. Working example 38 wasinferior in terms of an anti-reflection effect.

The second embodiment of the present invention adopts suchconfigurations as described above and therefore achieves such effects asfollows.

In the anti-reflection transfer member of the second embodiment of thepresent invention, at least the anti-reflection layer is provided on thesubstrate sheet, directly or with the mold release layer therebetween,the average surface roughness Ra of the surface of the substrate sheetor the surface of the mold release layer is between 2.0 and 150 nm, andtherefore the transfer member has the anti-reflection layers that areexcellent in uniformity in terms of thickness. Thus anti-reflectionmoldings having an excellent anti-reflection effect can be obtainedeasily, with use of the anti-reflection transfer member.

Third Embodiment

An embodiment of the present invention will be described in detail withreference to the drawings.

The transparent window of the conventional cover component is commonlyobtained by formation of a primer layer or a hard-coat layer on atransparent substrate and by formation thereon of a low-reflectancelayer.

In the cover component obtained by such a method, however, difficulty informing a smooth surface on a primer layer 411 or a hard-coat layercauses an issue in that diffused reflection (see an arrow 412) occurs atan interface between the surface and a low-reflectance layer 403, andmay impair comfort in viewing a liquid crystal panel screen positionedat a back of the cover component (see FIG. 31). Reference numeral 407denotes a transparent substrate.

The third embodiment is therefore intended for providing ananti-reflection member that obviates such a defect as described aboveand that has an excellent anti-reflection effect, and for providing amethod of manufacturing the same.

That is, the first and the second embodiments are present inventionsthat are basically based on an object of how to form anti-reflectionlayers on a surface with a uniform thickness, and the third embodimentis an invention that improves an inner layer structure on basis of anobject of how to scatter light having invaded inside, and how to preventreflection regardless of presence or absence of anti-reflection layers.

Thus, this embodiment is a technique different from the first and thesecond embodiments, and achievement of anti-reflection performance of ahigher degree is therefore expected with use thereof in combination withthe first and the second embodiments.

FIG. 26 is a sectional view illustrating an anti-reflection member ofthe third embodiment of the present invention. FIG. 27 is a sectionalview illustrating a transfer member for use in a method of manufacturingthe anti-reflection member of the third embodiment of the presentinvention. FIG. 28 is a perspective view illustrating theanti-reflection member of the third embodiment of the present invention.FIGS. 29 and 30 are sectional views illustrating steps of a method ofmanufacturing the anti-reflection member of the third embodiment of thepresent invention. In the third embodiment, FIG. 15 used in the firstembodiment is used also as a perspective view illustrating theanti-reflection member of the third embodiment of the present invention.FIG. 16 is used as a sectional view illustrating the anti-reflectionmember of the third embodiment of the present invention. FIG. 32 is asectional view illustrating the anti-reflection member of the thirdembodiment of the present invention. FIG. 33 is a sectional viewillustrating the anti-reflection member of the third embodiment of thepresent invention. FIG. 34 is a sectional view illustrating theanti-reflection member of the third embodiment of the present invention.

In the drawings, reference numeral 301 denotes the anti-reflectionmember, numeral 302 denotes an anti-fouling layer, numeral 303 denotes alow-reflectance layer, numeral 304 denotes an uneven layer, numeral 305denotes a pattern layer, numeral 306 denotes an adhesive layer, numeral307 denotes a transparent substrate, numeral 308 denotes a substratesheet, numeral 309 denotes a transfer member, numeral 310 denotes ametal mold, and numeral 312 denotes incident light.

In the anti-reflection member 301 of the present invention, twoanti-reflection component layers having an interface with an unevenshape between both the layers are stacked on a transparent window of thetransparent substrate 307 (see FIG. 26).

In order that the two anti-reflection component layers having theinterface with the uneven shape between both the layers may be providedon the transparent substrate 307, preferably used is a transferringmethod or a molding in-mold transferring method using the transfermember 309.

The transferring method is such a method as follows. The transfer member309 having transfer layers of various layers formed on the substratesheet 308 is used, heat and pressure are applied thereto to make thetransfer layers adhere onto an object of transfer, the substrate sheet308 is thereafter peeled off, and only the transfer layers aretransferred to a surface of the object of transfer to make decoration.The molding in-mold transferring method is such a method as follows. Thetransfer member 309 is interposed into the metal mold 310, molten resinis injected into the metal mold 310, a resin molding is obtained bycooling, the transfer member 309 is bonded onto a surface of the moldingsimultaneously with this obtainment, the substrate sheet 308 isthereafter peeled off, and transfer layers are transferred onto thesurface of the resin molding to make decoration.

In the present invention is used the transfer member 309 in which thetwo anti-reflection component layers having the interface with theuneven shape between both the layers are formed at least as the transferlayers on the substrate sheet 308 (see FIG. 27). As for the transferlayers, preferably, not all the layers that are to be formed on thetransparent substrate 307 of the anti-reflection member 301 areincorporated into the transfer layers, but only layers suitable forformation by the molding in-mold transferring method are the transferlayers, and other layers are formed separately. The uneven layer 304,the pattern layer 305, and the like are particularly suitable forformation by the molding in-mold transferring method.

As material of the substrate sheet 308 may be used material that is usedas a substrate sheet for conventional transfer member, for example, aresin sheet of polypropylene resin, polyethylene resin, polyamide resin,polyester resin, acrylic resin, polyvinyl-chloride resin, or the like.

Provided that peelability of the transfer layers from the substratesheet 308 is satisfactory, the transfer layers may be provided directlyon the substrate sheet 308. In order to improve the peelability of thetransfer layers from the substrate sheet 308, a mold release layer maybe formed before the transfer layers are provided on the substrate sheet308.

As occasion demands, the low-reflectance layer 303 is preferably formedon the substrate sheet 308 or the mold release layer. With provision ofthe low-reflectance layer 303, reflection of the incident light 312 canbe prevented more thoroughly.

As material of the low-reflectance layer 303 may be used a vapordeposited layer of a metal compound such as Al₂O₃, ZnO₂, or MgF₂; avapor deposited layer in which a metal compound having a low index ofrefraction such as SiO₂ or MgF₂ and a metal compound having a high indexof refraction such as ZnO₂ or TiO₂ are laminated; or a resin coatinglayer composed of fluoropolymer, silicon oxide gel, or the like, forexample. A combination of these materials may be used.

Among methods of manufacturing the low-reflectance layer 303 are avacuum deposition method, a sputtering technique, ion plating, and thelike. There also is a method in which the low-reflectance layer 303 isobtained by application of an organic metal compound such as metalalcoholate or metal chelate by performing a dipping method, a printingprocess, a coating process, or the like and subsequent formation ofmetal oxide film by performing photoirradiation or drying.

The low-reflectance layer 303 may be composed of only one layer having alow index of refraction or may be a complex layer of layer(s) with a lowindex of refraction and layer(s) with a high index of refraction. Use ofthe complex layer may improve an anti-reflection property. In order tocancel an increase in number of man-hours that may be caused by use ofthe complex layer, it is extremely efficient to form the low-reflectancelayer 303 by performing a roll-to-roll continuous coating process. Forsuch a transfer member 309 as in this embodiment, roll-to-rollcontinuous production can be achieved.

Preferably, a film thickness of the low-reflectance layer 303 isappropriately selected so as to satisfy a general expression nd=λ4 or ageneral expression nd=3λ/4 (wherein n is an index of refraction of asubstance with a low index of refraction, d is a film thickness of thesubstance with the low index of refraction, and λ is a low reflectioncentral wavelength). In ordinary cases, the thickness of thelow-reflectance layer 303 is in a range of 0.01 to 2 μm.

Subsequently, the uneven layer 304 is provided. By provision of theuneven layer 304 is formed an upper layer of two anti-reflectioncomponent layers having an interface with an uneven shape between boththe layers. As material of the uneven layer 304 is preferably usedacrylic resin, polyester resin, polyvinyl chloride resin, cellulosicresin, rubber resin, polyurethane resin, polyvinyl acetate resin, or thelike; or a copolymer such as vinyl chloride vinyl acetate copolymerresin or ethylene vinyl acetate copolymer resin, or the like. A hardnessof the uneven layer 304 can be increased with use of thermosettingresin, resin curable by ionizing radiation such as ultraviolet ray orelectron beam, or the like. Ultraviolet curable resins includeultraviolet curable acrylic urethane resin, ultraviolet curablepolyester acrylate resin, and ultraviolet curable epoxy acrylate resin,and are used with a photoinitiator. For example, ultraviolet curableacrylic urethane resin is obtained by reaction of polyester polyol withisocyanate monomer or prepolymer and by reaction of a resultant productwith acrylate or methacrylate monomer having hydroxyl groups. As thephotoinitiator may be used benzophenones, acetophenones, anthraquinonederivatives or the like, singly or in combination. For improvingformation of coating, thermoplastic acrylic resin or the like mayappropriately be selected and blended with ultraviolet curable resins.

Among methods of forming the uneven layer 304 are coating such asgravure coating, roll coating, or comma coating; or a printing processsuch as gravure or screen printing.

Among methods of forming an uneven surface of the uneven layer 304 are amethod in which the uneven layer 304 mixed with a light diffusing agentis applied directly onto a surface of the substrate, a method in whichthe surface of the uneven layer 304 is embossed, and the like.

As the light diffusing agent are preferably used silica beads, acrylicbeads, or the like subjected to organic coating process. In order thatthe light diffusing agent subjected to organic coating process may bedispersed in the uneven layer 304, a content of the light diffusingagent is preferably not more than 15 parts by weight per 100 parts ofink for the uneven layer 304.

With use of silica beads having particle sizes on the order of 0.4 to 8μm, uneven surfaces having various average surface roughnesses Ra wereformed on the uneven layers 304 of ultraviolet curable resin having athickness of 5 μm, total light transmittances and reflectances at 550 nmwere measured for verification of an anti-reflection effect, and it wasresultingly found that the average surface roughnesses were preferablycontrolled within a range of 0.2 to 1.0 μm (see Table 5).

On comparison between an example in which the anti-reflection member 301was manufactured by the method of manufacturing the anti-reflectionmember 301 of the third embodiment of the present invention and anexample in which the low-reflectance layer 303 was formed afterproduction of a molding, it was found that the example of the thirdembodiment of the present invention not only improved an anti-reflectioneffect but also tended to increase light transmittance a little (seeTable 6). A conceivable reason for that is that a part of incident light312 reflected irregularly by the uneven shape could not come out of thesurface easily because of repeated reflection by an interface betweenthe uneven layer 304 and the low-reflectance layer 303 and the like, ina structure in which the uneven shape resided inside the anti-reflectionmember 301 (see FIG. 26). Total light transmittance was measured onbasis of a method defined by Japanese Industrial Standard (JIS) K6714.

As occasion demands, the pattern layer 305 may be formed. The patternlayer 305 is a layer for decorating the anti-reflection member 301.Provided that the anti-reflection member 301 is a cover component for adisplay section, the pattern layer 305 is partially provided so as to beshaped like a frame, a letter, or the like in a pattern excluding thetransparent window, in ordinary cases. The pattern layer 305 is commonlyformed as a print layer. As material of the print layer is preferablyused colored ink that contains as binder such resin as polyvinyl resin,polyamide resin, polyester resin, acrylic resin, polyurethane resin,polyvinyl acetal resin, polyesterurethane resin, cellulose ester resin,or alkyd resin and that contains, as coloring agent, pigment or dye thathas an appropriate color. As methods of forming the print layer, aconventional printing process such as offset printing, gravure printing,and screen printing, or the like is employed preferably.

The pattern layer 305 may be composed of a metal thin film layer or acombination of a print layer and a metal thin film layer. The metal thinfilm layer is intended for expressing metallic luster in the patternlayer 305 and is formed by performing a vacuum deposition method,sputtering technique, ion plating, plating, or the like. Metal such asaluminum, nickel, gold, platinum, chromium, iron, copper, tin, indium,silver, titanium, lead, or zinc; or an alloy; or a compound of thesemetals is used in accordance with a desired color of metallic lusterthat is to be expressed. In ordinary cases, the metal thin film layer isformed partially. When the metal thin film layer is provided, apre-anchor layer and/or a post-anchor layer may be provided forimproving adhesion to other layers.

Adhesive layers 306 are formed for bonding the above-mentioned layersonto the transparent substrate 307. With contact between the unevenlayer 304 and the adhesive layer 306, the two anti-reflection componentlayers having the interface with the uneven shape between both thelayers are formed. For the adhesive layer 306 is appropriately usedheat-sensitive or pressure-sensitive resin suitable for material of thetransparent substrate 307.

Provided that the material of the transparent substrate 307 is acrylicresin, for example, acrylic resin is preferably used for the adhesivelayer. Provided that the material of the transparent substrate 307 ispolyphenylene oxide polystyrene resin, polycarbonate resin, orpolystyrene blend resin, preferably used is acrylic resin, polystyreneresin, polyamide resin, or the like that has an affinity for the aboveresins. Provided that the material of the transparent substrate 307 ispolypropylene resin, it is possible to use chlorinated polyolefin resin,chlorinated ethylene vinyl acetate copolymer resin, cyclized rubber, orcoumarone-indene resin. Among methods of forming the adhesive layer 306are coating such as gravure coating, roll coating, or comma coating; ora printing process such as gravure or screen printing.

A configuration of the transfer layers is not limited to theabove-mentioned manner. Provided that a transparent layer that isexcellent in terms of adhesiveness with respect to the transparentsubstrate 307 is used as the material of the pattern layer 305, forexample, the transparent layer serves as a lower layer of theanti-reflection component layers and therefore allows the adhesive layer306 to be omitted.

The anti-reflection component layers having the interface with theuneven shape are not limited to the combination of the uneven layer 304and the adhesive layer 306 or the combination of the uneven layer 304and the pattern layer 305 (see FIG. 26) but may be configured so as tobe made of a combination with other layers. For example, as shown inFIG. 32, a combination of the uneven layer 304 and an interlayer 330 maybe used. The interlayer 330 is preferably formed with use of materialsimilar to that of the uneven layer 304. As shown in FIG. 33, aconfiguration may be adopted such that an anti-reflection function isachieved by two uneven interfaces 332 having uneven shapes andconfigured by three layers of the uneven layer 304, the interlayer 330,and the adhesive layer 306.

Provided that the uneven interface 332 having an uneven shape isconfigured by two layers other than the adhesive layer 306, the adhesivelayer 306 can be formed with a uniform thickness regardless of sizes ofprojections and depressions in the uneven shape, so that adhesivenessthereof to the transparent substrate 308 can be stabilized. Providedthat the uneven interface 332 having an uneven shape is configured bytwo layers of the adhesive layer 306 and another layer, a number oflayers that constitute the anti-reflection member can be reduced by one.

Depending on uses of the anti-reflection member 301, a distinction maybe made on a surface of the member, between an area where excellentanti-reflection function is particularly required and an area where alittle decrease in anti-reflection function causes no noticeable issues.FIG. 15 is the perspective view illustrating an anti-reflection member301 that is used in a full-color liquid crystal display section of aportable telephone and that is 25 mm long and 33 mm wide, as an example.In the anti-reflection member 301 for such a use, a central area CA is aregion a user of the portable telephone watches most carefully, in otherwords, a visual recognition area in the transparent window, andtherefore is an area that particularly requires anti-reflectionfunction. By contrast, a marginal area CB that is a periphery of thecentral area CA and is a margin of the liquid crystal display section,in other words, a peripheral visual recognition area on periphery of thevisual recognition area in the transparent window is not the region auser of the portable telephone watches carefully, and the area CBtherefore does not require so high degree of an anti-reflectionfunction. The smaller a radius R of curvature of a surface shape of theanti-reflection member 301, the lower a degree of necessity for ananti-reflection function. Provided that a surface shape of theanti-reflection member 301 shown in FIG. 15 has a sectional shape shownin FIG. 16, for example, there is little possibility that a user of theportable telephone may carefully watch the extremely small area CBhaving a radius R of curvature smaller than 40 mm.

Accordingly, as shown in FIG. 34, the central area CA and the marginalarea CB may be configured so as to have different uneven shapes. Thatis, configured are an uneven interface 332B that is provided in thecentral area CA and that is greatly uneven, and an uneven interface 332Sthat is provided in the marginal area CB and that is slightly uneven.The different uneven shapes are preferably made with variation duringdegree of unevenness in an emboss process or other process.

With use of such an anti-reflection transfer member 309 configured asdescribed above, use of a transfer process may be made so that theanti-reflection member 301 may be obtained easily.

A side of the anti-reflection transfer member 309 having the adhesivelayer 306 is initially brought into intimate contact with a surface ofthe transparent substrate 307. With use of a transferring machine suchas roll transferring machine or up-down transferring machine providedwith a heat-resistant-rubber-like elastic body of silicone rubber or thelike, subsequently, heat and pressure are applied from a side of theanti-reflection transfer member 309 having the substrate sheet 308through the heat-resistant-rubber-like elastic body provided with acondition of a temperature on the order of 80 to 260° C. and of apressure on the order of 490 to 1960 Pa. By this process, the adhesivelayer 306 is bonded onto the surface of the transparent substrate 307.

Finally, the substrate sheet 308 is peeled off after being cooled,exfoliation is then caused at an interface surface between the substratesheet 308 and the low-reflectance layer 303, and the transfer iscompleted. On condition that the mold release layer is provided on thesubstrate sheet 308, peeling the substrate sheet 308 causes exfoliationat an interface surface between the mold release layer and thelow-reflectance layer 303 and completes the transfer. Thus, theanti-reflection member 301 is obtained.

There will now be described a method of obtaining the anti-reflectionmember 301 by making use of the molding in-mold transferring method byinjection molding with use of the above-mentioned anti-reflectiontransfer member 309.

As the metal mold 310 for molding, a metal mold for use in injectionmolding is used.

The transfer member 309 is initially delivered into the metal mold 310for molding (see FIG. 29). In this step, sheet-like transfer members 309may be delivered one by one or required portions of long-sized transfermember 309 may be delivered intermittently. In the case that thelong-sized transfer member 309 is used, a feeder having a positioningdevice is preferably used so that the pattern layer 305 of the transfermember 309 and the metal mold 310 for molding may be in register. Whenthe transfer member 309 is delivered intermittently, it is convenient tohold the transfer member 309 by a movable mold and a stationary moldafter detection of a position of the transfer member 309 by a sensor, inthat the transfer member 309 may be held in the same position at anytime and in that mis-registration of the pattern layer 305 is prevented.

After closure of the metal mold 310 for molding, molten resin isinjected from a gate into the metal mold 310 to fill the mold, an objectof transfer is formed and, simultaneously with this formation, thetransfer member 309 is made to adhere onto a surface of the object (seeFIG. 30).

As resin that may be used for the transparent substrate 307 may be namedgeneral-purpose resins such as polystyrene resin, polyolefin resin, ABSresin, AS resin, or AN resin. There also may be used general-purposeengineering resin such as polyphenylene oxide polystyrene resin,polycarbonate resin, polyacetal resin, acrylic resin, polycarbonatedenatured polyphenylene ether resin, polybutylene terephthalate resin,or ultragiant molecular weight polyethylene resin; and super engineeringresin such as polysulfone resin, polyphenylene sulfide resin,polyphenylene oxide resin, polyarylate resin, polyetherimide resin,polyimide resin, liquid crystalline polyester resin, or polyallylheat-resistant resin. These molding resins may be mixed with lightdiffusing agent composed of silica beads, acrylic beads, or the like; orthe like.

The transparent substrate 307 may have a tabular shape or a shapeincluding a two-dimensional or three-dimensional curved surface.

A resin molding as the object of transfer is cooled, the metal mold 310for molding is thereafter opened, and the resin molding is removed.Finally, the substrate sheet 308 of the transfer member 309 is peeledoff. Thus, only the transfer layers are transferred to the molding.

With integration of the transfer layers and molding resin in thismanner, there may be formed the anti-reflection member 301 in which thetwo anti-reflection component layers having the interface with theuneven shape between both the layers are stacked on the transparentwindow of the transparent substrate 307 (see FIGS. 26 and 28).

Provided that the anti-reflection member 301 obtained with use of thetransfer member 309 as described above does not have the low-reflectancelayer 303 formed therein, the low-reflectance layer 303 may be providedas occasion demands. The low-reflectance layer 303 can be formed as inthe case of formation as the transfer layers of the transfer member 309.

As occasion demands, the anti-fouling layer 302 may be provided. Theanti-fouling layer 302 is a layer that is provided on thelow-reflectance layer 303 to prevent contamination of theanti-reflection member 301 and that is composed of material havingwater-repellency and oil-repellency. For the anti-fouling layer 302 ispreferably used a surface active agent having fluorine in end groups, orthe like. The anti-fouling layer 302 is preferably provided byperforming a coating process, dipping method, vacuum deposition method,or the like. It is preferable for a thickness of the anti-fouling layer302 to be as small as possible. That is because a light transmittance ofthe anti-reflection member 301 decreases with increase in the thicknessof the anti-fouling layer 302.

Thus, the anti-reflection member 301 is configured so that the twoanti-reflection component layers having the interface with the unevenshape between both the layers are stacked on the transparent window ofthe transparent substrate 307, a part of incident light 312 reflectedirregularly by the uneven interface is reflected again by otherinterfaces and, therefore, light transmittance can be increased and agreater anti-reflection effect can be achieved in comparison with theconfiguration in which a glare-proof property is obtained by diffusedreflection by an uneven surface formed on an anti-reflection member.

Hereinbelow, more concrete examples of the third embodiment will bedescribed as working examples.

WORKING EXAMPLES 41 THROUGH 47

Polyethylene terephthalate resin films with a thickness of 25 μm wereused as substrate sheets, and the films were coated with melamine resinso that mold release layers were formed. Low-reflectance layers composedof silicon oxide with a thickness of about 0.1 μm were formed thereon.Ink for uneven layers in which eight parts by weight of silica beadshaving particle sizes on the order of 0.4 to 8.0 μm were added to 100parts by weight of ultraviolet curable resin (ARONIX M8030 produced byTOAGOSEI CO., LTD.) was prepared to form thereon uneven layers that wereuneven with various average surface roughnesses and that had a meanthickness of 5 μm. Adhesive layers were formed thereon with use ofacrylic adhesive ink and transfer members were thus obtained.

Acrylic films with a thickness of 125 μm were used as transparentsubstrates, were layered on the transfer members, and were bonded withheat and pressure applied from a side having the substrate sheet by aroll transferring machine, the substrate sheets were peeled off and wereremoved with the mold release layers, and obtained were anti-reflectionmembers having the low-reflectance layers, the uneven layers, and theadhesive layers formed sequentially from a surface side.

TABLE 5 Particle Surface size roughness of Total light of beads hardcoattrans- Reflec- (μm) layer (μm) mittance (%) tance (%) EvaluationContrast No 0.1 91 0.8 Δ example addition Working 0.4 0.1 86 0.8 ΔExample 41 Working 0.5 0.2 89 0.1 ∘ Example 42 Working 1.0 0.5 85 0.1 ∘Example 43 Working 3.0 0.8 82 0.1 ∘ Example 44 Working 5.0 1.0 75 0.1 ∘Example 45 Working 6.0 1.2 66 0.1 x Example 46 Working 8.0 1.6 49 0.1 xExample 47

Herein, evaluation “O” designates “good”, “Δ” designates “fair”, and “x”designates “failure”. As a result, it was found that the average surfaceroughness of the uneven layer was preferably within a range of 0.2 to1.0 μm. On condition that the average surface roughness exceeded 1.0 μm,light transmittance was considerably decreased so that a screen was hardto see.

WORKING EXAMPLE 42

A polyethylene terephthalate resin film with a thickness of 25 μm wasused as a substrate sheet, a mold release layer composed of melamineresin was formed thereon, sequentially formed by a multicolor gravureprinting press were a low-reflection layer composed of a layer having alow index of refraction, having a thickness of 0.09 μm, and using OPSTERJN7215 produced by JSR Corporation as ink for the layer having the lowindex of refraction and of a layer having a high index of refraction,having a thickness of 0.12 μm, using OPSTER JN7102 produced by JSRCorporation as ink for the layer having the high index of refraction; anuneven layer using ink for uneven layer in which eight parts by weightof silica beads having particle sizes of 0.5 μm were added to 100 partsby weight of ultraviolet curable resin (ARONIX M8030 produced byTOAGOSEI CO., LTD.); and an adhesive layer using adhesive ink of acrylicresin, and thus a transfer member was obtained.

The transfer member was loaded into an injection metal mold (a femalemold) that corresponded to a surface shape of a molding for a displaysection of a portable telephone, the metal mold was closed, acrylicmolding resin produced by Mitsubishi Rayon Co., Ltd. was injected, andan anti-reflection member that was the molding for the display sectionof the portable telephone was obtained.

As a contrast example 2, a molding was previously manufactured, theabove-mentioned four types of ink, i.e., adhesive ink, ink for an unevenlayer, ink for a layer having a high index of refraction, and ink for alayer having a low index of refraction were provided, in order ofmention, on the molding by performing dipping coating, and thus ananti-reflection member was obtained.

On comparison between the anti-reflection members thus obtained, thecontrast example 2 exhibited a tendency to have a large difference infilm thickness along a direction of application and was found to have alarge variation in anti-reflection performance in a surface thereof. Theworking example 48 was superior also in comparison concerningreflectance and light transmittance, at 550 nm. Moreover, the workingexample 48 was superior also in terms of productivity.

TABLE 6 Working Example 48 Contrast example 2 Thickness of layer 0.09 ±0.01 0.09 ± 0.04 having low index of refraction (μm) Thickness of layer0.12 ± 0.01 0.12 ± 0.05 having high index of refraction (μm) Thicknessof uneven 5.1 ± 0.6 5.1 ± 0.6 layer (μm) Thickness of 1.8 ± 0.4 1.8 ±0.5 adhesive layer (μm) Reflectance of 0.0~0.3 0.8~5.2 molding surface(%) Light transmittance 89 86 of molding (%)

The third embodiment of the present invention adopts such aconfigurations as described above and therefore achieves such effects asfollows.

In the anti-reflection member of the third embodiment of the presentinvention, the two anti-reflection component layers having the interfacewith the uneven shape between both the layers are stacked on thetransparent window of the transparent substrate, and the anti-reflectionmember therefore has an excellent anti-reflection effect.

In the anti-reflection member of the third embodiment of the presentinvention and the method of manufacturing the same, the transfer memberin which at least the two anti-reflection component layers having theinterface with the uneven shape between both the layers are formed onthe substrate sheet is set in the metal mold so that the substrate sheetcomes into contact with its cavity surface, transparent molten resin isinjected into the metal mold so that an integrated body of thetransparent substrate formed of the resin and the transfer member isobtained, the substrate sheet is subsequently peeled off, and thus theanti-reflection member having an excellent anti-reflection effect can beobtained easily.

Arbitrary embodiments among the above-mentioned various embodiments maybe combined appropriately so that the effects the embodiments have maybe achieved.

For example, FIG. 35 is a sectional view illustrating an anti-reflectionmember in accordance with a combination of the first embodiment and thethird embodiment of the present invention. That is, in a central areaCA, the member is composed of high-degree anti-reflection layers 202Hcomposed of a plurality of layers, a hard-coat layer 331, an interlayer330, an adhesive layer 306, and a substrate 308, an average surfaceroughness Ra of a surface of the hard-coat layer 331 is between 5 and 35nm, and an interface between the interlayer 330 and the adhesive layer306 is an uneven interface 332B having great unevenness. In a marginalarea CB, the member is composed of low-degree anti-reflection layers202L, the hard-coat layer 331, the interlayer 330, the adhesive layer306, and the substrate 308, an average surface roughness Ra of thesurface of the hard-coat layer 331 is between 35 and 150 nm, and aninterface between the interlayer 330 and the adhesive layer 306 is anuneven interface 332S having a little unevenness. Thus, the effects ofthe first embodiment and of the third embodiment can be achievedcollectively.

FIG. 36 is a sectional view illustrating an anti-reflection member inaccordance with a combination of the second embodiment and the thirdembodiment of the present invention. That is, in a central area CA, themember is composed of a substrate sheet 201, a mold release layer 220Hhaving a small average surface roughness Ra, high-degree anti-reflectionlayers 202H composed of a plurality of layers, a hard-coat layer 331,and an adhesive layer 306, and an interface between the hard-coat layer331 and the adhesive layer 306 is an uneven interface 332B having greatunevenness. In a marginal area CB, the member is composed of thesubstrate sheet 201, a mold release layer 220L having an average surfaceroughness Ra on the order of 110 to 140 nm, i.e., in a range in which aminimal anti-reflection effect may be obtained, a low-degreeanti-reflection layer 202L, the hard-coat layer 331, and the adhesivelayer 306, and an interface between the hard-coat layer 331 and theadhesive layer 306 is an uneven interface 332S having a littleunevenness. Thus, the effects of the second embodiment and of the thirdembodiment can be achieved collectively.

In those structures in which two embodiments are combined, light thatcomes to the uneven interface is scattered in the vicinity of theinterface and is brightened by a diffusion effect. On the other hand,light in the vicinity of the anti-reflection layers that are outermostlayers is cancelled by interference. Thus, a bright screen is achievedbut the brightness causes no glare, and a display screen that may beviewed extremely comfortably by viewers and that is easy on eyes isachieved.

Application of the present invention to electronic paper, that is anelectronic display device as light, thin, and flexible as paper,requires a function such that the molding as electronic paper may befolded, and therefore requires flexibility of the anti-reflectionlayers, and material of the anti-reflection layers is preferably a resincoating layer. In addition, an anti-fouling layer is preferablyprovided.

Although the present invention has been fully described in connectionwith the preferred embodiments thereof with reference to theaccompanying drawings, it is to be noted that various changes andmodifications are apparent to those skilled in the art. Such changes andmodifications are to be understood as included within the scope of thepresent invention as defined by the appended claims unless they departtherefrom.

1. A method of manufacturing anti-reflection molding, comprising:placing a decorating sheet having at least a hard-coat layer formed on asubstrate sheet to come a substrate sheet side thereof into contact witha cavity surface of a mold that is a curved surface having a radius ofcurvature of not less than 40 mm or a flat surface in an areacorresponding to a transparent window; injecting transparent moltenresin into the mold to obtain an integrated body of the decorating sheetand of a transparent substrate composed of the resin; subsequentlypeeling the substrate sheet from the integrated body to form a curvedsurface having a radius of curvature of not less than 40 mm andprotruding on a surface side thereof or a flat surface that has anaverage surface roughness Ra of between 2.0 and 150 nm in thetransparent window; and subsequently forming an anti-reflection layer ona surface side of the transparent substrate.
 2. A method ofmanufacturing anti-reflection molding, comprising: placing a decoratingsheet having at least a hard-coat layer formed on a substrate sheet tocome a side having the hard-coat layer into contact with a cavitysurface of a mold that is a curved surface having a radius of curvatureof not less than 40 mm or a flat surface in an area corresponding to atransparent window; injecting transparent molten resin into the mold toobtain an integrated body of the decorating sheet and of a transparentsubstrate composed of the resin and to form a curved surface having aradius of curvature of not less than 40 mm and protruding on a surfaceside thereof in a shape of the transparent window or a flat surface thathas an average surface roughness Ra of between 2.0 and 150 nm in thetransparent window; and subsequently forming an anti-reflection layer ona surface side of the transparent substrate.
 3. A method ofmanufacturing anti-reflection molding as claimed in any one of claims 1and 2, wherein the decorating sheet has the allover hard-coat layer, apartial pattern layer with a pattern excluding the transparent window,and an allover adhesive layer that are formed at least on the substratesheet.
 4. A method of manufacturing anti-reflection molding as claimedin claim 3, wherein an antifouling layer is formed on theanti-reflection layer.
 5. A mold for anti-reflection molding by which ananti-reflection molding is molded that has at least a hard-coat layerformed on a surface of a transparent substrate and that has a curvedsurface having a radius of curvature of not less than 40 mm andprotruding on a surface side thereof in a transparent window or a flatsurface with an average surface roughness Ra of between 2.0 and 150 nmin the transparent window, the mold for anti-reflection molding, havinga cavity surface that is a curved surface having a radius of curvatureof not less than 40 mm or a flat surface in an area corresponding to thetransparent window.
 6. A mold for anti-reflection molding as claimed inclaim 5, wherein the cavity surface has an average surface roughness Raof between 2.0 and 170 nm in the area corresponding to the transparentwindow.
 7. A method of manufacturing anti-reflection member, comprising:setting a transfer member wherein at least two anti-reflection componentlayers having interfaces with uneven shapes between both the layers areformed on a substrate sheet, in a mold to come the substrate sheet intocontact with a cavity surface; injecting transparent molten resin intothe mold to obtain an integrated body of the transfer member and atransparent substrate composed of the resin; and subsequently peelingthe substrate sheet from the integrated body.
 8. A method ofmanufacturing anti-reflection member as claimed in claim 7, wherein theuneven shape exhibits an average surface roughness Ra of between 0.2 and1.0 μm.
 9. A method of manufacturing anti-reflection member as claimedin any one of claims 7 and 8, wherein an upper layer of theanti-reflection component layers is composed of thermosetting resin,ultraviolet curable resin, or electron beam curable resin.
 10. A methodof manufacturing anti-reflection member as claimed in any one of claims7 and 8, wherein a low-reflectance layer having a reflectance lower thanthat of the upper layer is formed on the upper layer of theanti-reflection component layers.
 11. A method of manufacturinganti-reflection member as claimed in claim 10, wherein an antifoulinglayer is formed on the low-reflectance layer.
 12. A method ofmanufacturing anti-reflection member as claimed in any one of claims 7and 8, wherein a pattern layer is formed outside the transparent window.13. An anti-reflection molding comprising: a transparent substrate, atransparent window and an anti-reflection layer arranged relative to oneanother such that said transparent window is positioned between saidtransparent substrate and said anti-reflection layer, wherein saidanti-reflection layer is on a surface of said transparent window suchthat said surface defines an interface between said anti-reflectionlayer and said transparent window, with said interface having an averagesurface roughness Ra of between 2 nm and 150 nm, and said surface ofsaid transparent window (i) being convex and having a radius ofcurvature of at least 40 mm, or (ii) being planar.
 14. Theanti-reflection molding according to claim 13, further comprising: apartial pattern layer having a pattern between said transparentsubstrate and said anti-reflection layer, said partial pattern layercovering only a portion of said transparent window such that a remainingportion of said transparent window is not covered by said partialpattern layer.
 15. The anti-reflection molding according to any one ofclaims 13 or 14, further comprising: a hard-coat layer between saidtransparent substrate and said anti-reflection layer, wherein saidtransparent window is at least partially defined by said hard-coatlayer.
 16. The anti-reflection molding according to claim 15, furthercomprising: an anti-fouling layer on said anti-reflection layer.
 17. Theanti-reflection molding according to any one of claims 13 or 14, whereina portion of said interface corresponding to a central visualrecognition area of said transparent window has an average surfaceroughness Ra of between 2 nm and 35 nm, and a portion of said interfacecorresponding to a peripheral visual recognition area of saidtransparent window, along a periphery of said central visual recognitionarea, has an average surface roughness Ra of between 35 nm and 85 nm.18. An anti-reflection transfer member comprising: a substrate sheet;and an anti-reflection layer on a surface of said substrate sheet,wherein (i) said anti-reflection layer is directly on said surface ofsaid substrate sheet, with said surface of said substrate sheet havingan average surface roughness Ra of between 2 nm and 150 nm, or (ii) amold release layer is between said anti-reflection layer and saidsurface of said substrate sheet, with a surface of said mold releaselayer facing said anti-reflection layer having an average surfaceroughness Ra of between 2 nm and 150 nm.
 19. The anti-reflectiontransfer member according to claim 18, wherein said surface of saidsubstrate sheet has an average surface roughness Ra of between 5 nm and140 nm when said anti-reflection layer is directly on said surface ofsaid substrate sheet, or said surface of said mold release layer facingsaid anti-reflection layer has an average surface roughness Ra ofbetween 5 nm and 140 nm when said mold release layer is between saidanti-reflection layer and said surface of said substrate sheet.
 20. Theanti-reflection transfer member according to claim 19, wherein saidsurface of said substrate sheet has an average surface roughness Ra ofbetween 5 nm and 80 nm when said anti-reflection layer is directly onsaid surface of said substrate sheet, or said surface of said moldrelease layer facing said anti-reflection layer has an average surfaceroughness Ra of between 5 nm and 80 nm when said mold release layer isbetween said anti-reflection layer and said surface of said substratesheet.
 21. The anti-reflection transfer member according to any one ofclaims 18 through 20, further comprising: a hard-coat layer on saidanti-reflection layer, with said hard-coat layer being one of anultraviolet curable resin, an electron beam curable resin and athermosetting resin.
 22. The anti-reflection transfer member accordingto any one of claims 18 or 19, further comprising: a transparent window;and a pattern layer covering only a portion of said transparent windowsuch that a remaining portion of said transparent window is not coveredby said pattern layer.
 23. An anti-reflection member comprising: a firstanti-reflection component layer and a second anti-reflection componentlayer stacked on a transparent window of a transparent substrate,wherein an interface between said first and second anti-reflectioncomponent layers is uneven.
 24. The anti-reflection member according toclaim 23, wherein said interface exhibits an average surface roughnessRa of between 0.2 μm and 1.0 μm.
 25. The anti-reflection memberaccording to any one of claims 23 or 24, wherein an upper one of saidfirst and second anti-reflection component layers is one of anultraviolet curable resin, an electron beam curable resin and athermosetting resin.
 26. The anti-reflection member according to claim24, further comprising: a low reflectance layer on said upper one ofsaid first and second anti-reflection component layers, with said lowreflectance layer having a reflectance lower than a reflectance of saidupper one of said first and second anti-reflection component layers. 27.The anti-reflection member according to claim 26, further comprising: ananti-fouling layer on said low reflectance layer.
 28. Theanti-reflection member according to any one of claims 23 and 24, furthercomprising: a pattern layer covering only a portion of said transparentwindow such that a remaining portion of said transparent window is notcovered by said pattern layer.
 29. An anti-reflection moldingcomprising: a transparent substrate; a first anti-reflection componentlayer and a second anti-reflection component layer stacked on saidtransparent substrate, with an interface between said first and secondanti-reflection component layers being uneven; a hard-coat layer on thestacked first and second anti-reflection component layers, with saidhard-coat layer and the stacked first and second anti-reflectioncomponent layers defining a transparent window; and an anti-reflectionlayer on a surface of said transparent window such that said surfacedefines an interface between said anti-reflection layer and saidtransparent window, wherein said interface has an average surfaceroughness Ra of between 2 nm and 150 nm, and said surface of saidtransparent window (i) is convex and has a radius of curvature of atleast 40 mm, or (ii) is planar.
 30. An anti-reflection transfer membercomprising: a substrate sheet; an anti-reflection layer on a surface ofsaid substrate sheet, wherein (i) said anti-reflection layer is directlyon said surface of said substrate sheet, with said surface of saidsubstrate sheet having an average surface roughness Ra of between 2 nmand 150 nm, or (ii) a mold release layer is between said anti-reflectionlayer and said surface of said substrate sheet, with a surface of saidmold release layer facing said anti-reflection layer having an averagesurface roughness Ra of between 2 nm and 150 nm; and a firstanti-reflection component layer and a second anti-reflection componentlayer stacked on said anti-reflection layer, with an interface betweensaid first and second anti-reflection component layers being uneven. 31.The anti-reflection molding according to claim 21, wherein saidultraviolet curable resin is selected from the group consisting ofultraviolet curable acrylic urethane resin, ultraviolet curablepolyester acrylate resin, and ultraviolet curable epoxy acrylate resin.